JP2005112673A - Apparatus and method for forming optical element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an apparatus and a method for forming an optical element through press-forming using a concave mold, wherein variation in thickness of the optical element can be inhibited, life of the mold can be managed and cost for pretreatment of a preform material can be reduced. <P>SOLUTION: In the apparatus, the preform material 4 is placed between a cylindrical concave mold 1 and upper and lower dies 2a and 2b which are located inside the concave mold 1, the concave mold 1, the upper and lower dies 2a and 2b and the preform material 4 are heated, and the upper and lower dies 2a and 2b are moved to perform press-forming of the optical element. Here, molding conditions such as press force at pressing are optimized according to the height of the mold or the height and size of the preform immediately before forming, by measuring the height of the lower die 2b before placing the preform material 4 and the height and size of the preform material 4 when placing the preform 4 inside the lower die 2b. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an optical element molding method and apparatus for molding optical elements such as lenses, mirrors, and prisms used for optical equipment by press molding a preform material.

  Conventional optical lenses such as cameras have been manufactured by a process such as polishing. However, in recent products that use optical elements such as DSCs, video cameras, and laser printers, their performance, size, and weight are reduced. Aspherical lenses are often used to reduce the cost and cost. In particular, a method of press-molding glass is used to manufacture a high-performance glass aspherical lens that cannot be handled by a resin aspherical lens by injection molding (see, for example, Patent Document 1).

  A general lens molding apparatus and molding process by conventional glass press molding will be described with reference to FIG. In FIG. 5, in the set stage S1, a cylindrical body mold 1, a lower mold 2b fixed in the body mold 1, and an upper portion arranged so as to be movable in the body mold 1 relative to the lower mold 2b. A preform material 4 made of a resin or glass material is supplied between the molds 2a, and the outer cylinder mold 3 adjusted to an arbitrary height dimension so as to have a predetermined lens thickness is set outside the cylinder mold 1. The preform material 4 is arbitrarily selected depending on the lens shape, such as a spherical shape as shown in FIG. 5, a cylindrical shape, or a shape molded to a shape close to the final lens shape. Next, the molding die composed of the barrel die 1, the upper and lower dies 2a, 2b and the outer barrel die 3 is moved to the charging stage S2, and the shutter 5 at the entrance of the molding apparatus is opened and transferred to the preheating stage S3. The inside of the molding apparatus is maintained in a nitrogen atmosphere with a structure that takes into account the degree of sealing so that the oxygen concentration can be controlled. In the preheating stage S3, the mold is preheated by the preheating device 6, and after completion of the preheating, the mold is transferred to the molding stage S4. After the mold temperature is raised to the moldable temperature on the molding stage S4, the preform material 4 is pressurized by the upper heater block 7. The lens thickness is controlled by the height of the outer shell mold 3. After a certain period of pressurization, the temperature of the upper and lower heaters is lowered and the mold temperature is lowered to a temperature at which the glass does not deform. Thereafter, the heater block 7 is raised, and then the shutter 8 at the outlet of the molding apparatus is opened, the molding die is taken out, and transferred to the cooling stage S5. Then, the mold is cooled to a temperature at which it can be taken out, transferred to the take-out stage S6, and the molded lens 9 is taken out.

As a form of conveyance of the lens before and after pressing, a system in which conveyance is performed by a set of molding dies including the body mold 1 and the upper and lower molds 2a and 2b from the setting of the preform material 4 to the removal of the molded lens 9 is the mainstream. In this way, by adjusting the clearance between the upper mold 2a and the lower mold 2b with respect to the body mold 1, required accuracy such as the coaxiality of the molded lens 9 is secured. Separately, a method of giving the body mold 1 a carrier function is also shown (for example, see Patent Document 2).
Japanese Patent Laid-Open No. 5-17168 Japanese Patent Application Laid-Open No. 5-270846

  By the way, in the manufacture of the optical element by press molding as described above, the stage is circulated by using a large number of dies to shorten the tact time. It is said that the mold bottom surface and the bottom surface and top surface of the outer body mold are worn by repeated transfer of the mold between the stages, and the height of each member varies, resulting in variations in the thickness of the molded lens 9 over time. There's a problem. In addition, uneven wear on the bottom surface of the mold causes contact with the heater block, resulting in poor accuracy of the molded lens 9 due to poor temperature rise. Further, in a severe case, there is a problem that an accident such as an overpack may be caused due to the combination with the volume variation of the glass material.

  Therefore, at present, the volume management standard of the preform material 4 is strict and the nonconforming preform material 4 is handled in such a way that it is not put into the line. Therefore, the accuracy of the inspection process, sphere, cylinder, approximate lens shape, etc. There is a problem that considerable cost must be spent for pre-processing to increase Even when the outer body mold 3 is not used, the bottom surface portion of the lower mold 2b is worn, so that the variation in the thickness of the molded lens 9 after pressing is a big problem. In the current process, the thickness failure and accuracy failure of the molded lens 9 are confirmed in the inspection process after molding, which is one of the factors that deteriorate the yield.

  In addition, as for the lens conveyance form before and after pressing, the upper and lower molds 2a and 2b are necessary as a set in any of the above methods, and it is necessary to have a large number of molds in order to reduce tact time, which increases the initial investment. There is a problem of inviting. For this reason, there is a problem that it is very strict in terms of cost to deal with small-lot products.

  In view of the above-mentioned conventional problems, the present invention can suppress the variation in the thickness of the optical element and manage the life of the mold in the manufacture of the optical element by press molding using the body mold, and can also perform pretreatment of the preform material. It is an object of the present invention to provide an optical element molding method and apparatus that can reduce costs and reduce initial investment.

  The optical element molding method and apparatus according to the first and seventh aspects of the present invention include a step of placing a preform material between a cylindrical body mold and an upper and lower molds disposed therein, A molding method comprising a step of heating a mold and a preform material, and a step of press-molding an optical element by moving the upper and lower molds, the step of measuring the height of the mold before the step of placing the preform material In addition, a preform material is arranged between the cylindrical body mold and the upper and lower molds disposed therein, and the optical element is pressed by moving the upper and lower molds by heating the body mold, the upper and lower molds and the preform material. A molding apparatus for molding is provided with means for measuring the height of a mold before placing a preform material.

  According to this configuration, the height state of the mold immediately before molding can be managed, optimization of molding conditions such as the indentation amount during pressing, and the wear state of the mold can be grasped. Therefore, it is possible to reduce the variation in the thickness of the molding optical element caused by the variation in the mold height, and to extract the mold with severe wear, thereby preventing the introduction to the line and improving the overall yield. Can do.

  The optical element molding method and apparatus according to the invention described in claim 2 and claim 8 include a step of measuring the height and size of the preform material when the preform material is placed in the mold, and the preform. Means are provided for measuring the height and size of the preform material when the material is placed in the mold.

  According to this configuration, the height and size of the preform material immediately before molding can be managed, and molding conditions such as the amount of pressing during pressing can be optimized. Therefore, it is possible to reduce the variation in the thickness of the molding optical element caused by the variation in the preform material, and to provide a margin for the volume management width of the preform material itself, and the pretreatment cost of the preform material is also increased. Can be reduced.

  The optical element molding method and apparatus according to the third and ninth aspects of the present invention include measuring the height of a mold before the step of placing the preform material and performing the preform when the preform material is placed in the mold. Means for measuring the height and size of the material, and means for measuring the height of the mold before placing the preform material, and the height of the preform material when placing the preform material in the mold. And means for measuring the size.

  According to this configuration, the height state of the mold immediately before molding can be managed, optimization of molding conditions such as the indentation amount during pressing, and the wear state of the mold can be grasped. Therefore, it is possible to reduce the variation in the thickness of the molding optical element caused by the variation in the mold height, and to extract the mold with severe wear, thereby preventing the introduction to the line and improving the overall yield. Can do. Further, the height and size of the preform material immediately before molding can be managed, and the molding conditions such as the amount of pressing during pressing can be optimized. Therefore, it is possible to reduce the variation in the thickness of the molding optical element caused by the variation in the preform material, and to provide a margin for the volume management width of the preform material itself, and the pretreatment cost of the preform material is also increased. Can be reduced.

  The optical element molding method and apparatus according to the fourth and tenth aspects of the present invention use a non-contact measuring mechanism for measuring the mold and the preform material, and the measuring means for the mold and the preform material is a non-contact measurement. It consists of means.

  According to this configuration, the preform material and the mold can be measured without scratches or dents, so that appearance defects such as scratches are not generated in the molded optical element.

  The optical element molding method and apparatus according to the fifth and eleventh aspects of the present invention have a plurality of lower molds with respect to one upper mold, and a preform material and an optical element after pressing are applied to these lower molds. A carrier function for transporting is provided, and a plurality of lower molds are provided for one upper mold, and these lower molds are provided with a carrier function for transporting preform materials and pressed optical elements.

  According to this configuration, the molding system is equipped with a high-precision repeat positioning mechanism for the lower mold, and a molding process configuration in which a plurality of lower molds are circulated with respect to one upper mold, the total money constituting the molding system. The number of molds can be reduced to about half of the conventional type, and the initial investment can be reduced. Further, in the cooling process after pressing, the carrier mold and the upper mold are separated from each other, so that the heat capacity of the carrier mold is reduced, the cooling efficiency is increased, and the total tact can be shortened.

  The optical element molding method and apparatus of the invention described in claims 6 and 12 has a plurality of lower molds for one upper mold, and preform materials and pressed optical elements are provided in these lower molds. It has a carrier function to convey and has a measuring process of molds and preform materials during the process of placing preform materials on the lower mold offline or in-line, and multiple lower molds for one upper mold These lower molds are equipped with a carrier function to transport preform materials and optical elements after pressing, and measurements of molds and preform materials are performed during the process of placing preform materials on the lower mold offline or in-line. The measuring means to perform is provided.

  According to this configuration, the molding system is equipped with a high-precision repeat positioning mechanism for the lower mold, and a molding process configuration in which a plurality of lower molds are circulated with respect to one upper mold, the total money constituting the molding system. The number of molds can be reduced to about half of the conventional type, and the initial investment can be reduced. Further, in the cooling process after pressing, the carrier mold and the upper mold are separated from each other, so that the heat capacity of the carrier mold is reduced, the cooling efficiency is increased, and the total tact can be shortened. Furthermore, the height state of the mold immediately before molding can be managed, optimization of molding conditions such as the amount of pressing during pressing, and the wear state of the mold can be grasped. Therefore, it is possible to reduce the variation in the thickness of the molding optical element caused by the variation in the mold height, and to extract the mold with severe wear, thereby preventing the introduction to the line and improving the overall yield. Can do. Then, the height and size of the preform material immediately before molding can be managed, and the molding conditions such as the amount of pressing during pressing can be optimized. Therefore, it is possible to reduce the variation in the thickness of the molding optical element caused by the variation in the preform material, and to provide a margin for the volume management width of the preform material itself, and the pretreatment cost of the preform material is also increased. Can be reduced.

  According to the optical element molding method and apparatus of the present invention, it is possible to optimize the mold life and molding conditions of the optical element by providing the function of measuring the mold height and the degree of wear before pressing, and variation in the thickness. It is possible to obtain a highly accurate optical element with little. In addition, by providing the function to measure the height and volume of the preform material before pressing, not only can the thickness variation of the molding element be suppressed, but the volume control range of the preform material can be increased. The cost for preprocessing can be reduced. Furthermore, by circulating a plurality of lower molds, it is possible to realize an optical element molding apparatus that suppresses the initial investment in the number of mold surfaces. By combining these, it is possible to realize an optical element molding method and apparatus with little variation in wall thickness, low pre-treatment cost of the preform material, and less initial investment.

  Hereinafter, an embodiment of an optical element molding method and apparatus according to the present invention will be described with reference to FIGS. In addition, about the same component as the prior art example demonstrated with reference to FIG. 5, the same referential mark is attached | subjected and description is abbreviate | omitted.

  In FIG. 1, the optical element molding apparatus according to the present embodiment includes a molding chamber 10 having a structure in which the degree of sealing is taken into consideration so that the oxygen concentration can be controlled and capable of being maintained in a nitrogen atmosphere. A rotary table 11 is disposed in the lower part of the molding chamber 10, a supply / discharge zone 12 is provided on one side of the shaft core 11a, and a press zone 13 is provided on the other side. A plurality of lower molds 2b are fixed on the rotary table 11 at equal intervals in the circumferential direction, so that the lower mold 2b is moved to a predetermined position in the supply / discharge zone 12 and a predetermined position in the press zone 13 by intermittent rotation of the rotary table 11. The lower mold 2b is configured to have a carrier function. In the press zone 13, one upper mold 2 a and a body mold 1 are disposed so as to be capable of moving up and down at a predetermined position where the lower mold 2 b stops, and the press control unit 14 performs a pressing operation. Yes. A heater 15 is disposed around the upper mold 2a and the trunk mold 1 so as to heat the trunk mold 1, the upper mold 2a, and the lower mold 2b by an induction heating method or a resistance heating method. The lower mold 2 b is not fixed to the rotary table 11, but the lower mold 2 b is supplied and temporarily fixed on the rotary table 11 in the supply / discharge zone 12, and the upper mold 2 a and the body mold 1 are fixed in the press zone 13. You may make it fix this after adjusting a position.

  As shown in FIG. 2, the rotary table 11 is raised by a guided cylinder 16, moved by a predetermined rotational angle by a rotation driving means 17, and then lowered by a guided cylinder 16, so that a taper guide 18 and a taper pin 19 are moved. By being engaged, it is positioned at a predetermined position. With such a configuration, even if the clearance between the body mold 1 and the lower mold 2b is set to 6 μm or less, a plurality of lower molds 2b can be repeatedly positioned with respect to one body mold 1 and the upper mold 2a and press-molded. Position accuracy is realized.

  The supply / discharge zone 12 is provided with a shutter 20 for suppressing the oxygen concentration in the molding chamber 10 and is opened and closed only when the preform material 4 and the molded lens 9 are supplied / discharged. The supply and discharge of the preform material 4 and the molded lens 9 are configured such that a manipulator 21 is taken in and out of each folder 22.

  Further, a height measuring device 23 is installed in the supply / discharge zone 12. As shown in FIG. 3, the height measuring instrument 23 measures the height of the lower mold 2 b every time and feeds back the height data to the press control unit 14. Further, if there is a lower mold 2b having a height outside the standard at the time of measurement, it is removed without proceeding to the next process.

  Further, after the preform material 4 is supplied to the lower mold 2b, the height measuring device 23 measures the height and volume of the preform material 4 as shown in FIG. For example, in the case of the spherical preform material 4, it is measured every time with the height measuring device 23 from the state placed on the lower mold 2 b, the volume is calculated from the height, and the data is fed back to the press control unit 14. Yes.

  In this way, the height data of the lower mold 2b and the height and volume data of the preform material 4 are fed back to the press control unit 14, and the press control unit 14 determines the pressing condition at the time of pressing based on those data every time. As a result, the accuracy of keeping the thickness variation of the molded lens 9 to 20 μm or less can be cleared without causing any overpack. This also increases the margin of the volume management standard of the preform material 4 and can reduce the cost related to the pretreatment cost. If the volume of the preform material 4 is unknown only by its height, it is necessary to measure the volume using recognition by a camera or the like.

  Although the micrometer is used for the height measuring device 23 in the illustrated example, it is more preferable to use a non-contact method such as a laser length measuring device because there is no fear of dents and scratches due to measurement.

  Next, a series of molding processes with the above configuration will be described. First, height data and the like of the lower mold 2 b positioned at a predetermined position in the supply / discharge zone 12 are measured by the height measuring device 23. Next, the preform material 4 gripped by the manipulator 21 is supplied to the lower mold 2b. Thereafter, the shape of the preform material 4 is also measured by the height measuring device 23 and compared with the measurement data of the lower mold 2b, and the optimum molding conditions are set.

  Next, the rotary table 11 rotates and the lower mold 2b is replaced. The upper die 2a, the barrel die 1 fixed thereto, and the heater 15 are lowered toward the lower die 2b transferred to the press zone 13 to the point just before the upper die 2a contacts the preform material 4, and are raised by the heater 15. The temperature starts.

  When the pressable temperature is reached, the upper die 2a is further lowered to press the preform material 4, and the pressing is completed under the optimum conditions. Thereafter, after the mold temperature is lowered to a temperature at which the glass is not deformed, the upper mold 2a is raised, the rotary table 11 is rotated, and the lower mold 2b holding the molded lens 9 pressed in the supply / discharge zone 12 is transferred. . The molded lens 9 is further cooled to a temperature at which it can be taken out, and is then discharged out of the apparatus by the manipulator 21 again.

  The optical element molding method and apparatus according to the present invention optimizes the molding conditions of the optical element by measuring the mold height and degree of wear, the height and volume of the preform material, etc. before pressing, and has a small thickness variation. Since an accurate optical element can be obtained, it is useful for molding various high-precision optical elements such as an aspherical lens such as a DSC or a video camera.

It is a longitudinal cross-sectional view which shows schematic structure of one Embodiment of the optical element shaping | molding method and apparatus of this invention. It is a block diagram of the rotary table in the embodiment. It is explanatory drawing of the measurement state of the height of the lower mold | type in the embodiment. It is explanatory drawing of the measurement state of the height of the preform raw material in the embodiment. It is a schematic block diagram of the optical element shaping | molding method and apparatus of a prior art example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Body type | mold 2a Upper type | mold 2b Lower type | mold 4 Preform material 11 Rotary table 14 Press control part 23 Height measuring device

Claims (12)

The process of placing the preform material between the cylindrical body mold and the upper and lower molds disposed therein, the process of heating the body mold, the upper and lower molds and the preform material, and moving the upper and lower molds to press the optical element An optical element molding method comprising a molding step comprising a step of measuring a mold height before a step of placing a preform material. The process of placing the preform material between the cylindrical body mold and the upper and lower molds disposed therein, the process of heating the body mold, the upper and lower molds and the preform material, and moving the upper and lower molds to press the optical element An optical element molding method comprising: a molding method comprising a molding step, the method comprising a step of measuring the height and size of a preform material when the preform material is placed in a mold. The process of placing the preform material between the cylindrical body mold and the upper and lower molds disposed therein, the process of heating the body mold, the upper and lower molds and the preform material, and moving the upper and lower molds to press the optical element A molding method comprising a molding process, in which the height of the mold is measured before the preform material is placed and the height and size of the preform material is measured when the preform material is placed in the mold. An optical element molding method comprising the step of: The optical element molding method according to claim 1, wherein a non-contact measuring mechanism is used for measuring the mold and the preform material. The process of placing the preform material between the cylindrical body mold and the upper and lower molds disposed therein, the process of heating the body mold, the upper and lower molds and the preform material, and moving the upper and lower molds to press the optical element A molding method comprising a molding step, wherein a plurality of lower molds are provided for one upper mold, and these lower molds have a carrier function for transporting preform materials and optical elements after pressing. An optical element molding method. There are multiple lower molds for one upper mold, these lower molds have a carrier function to transport preform materials and pressed optical elements, and preform materials can be transferred to the lower mold offline or in-line. The optical element molding method according to any one of claims 1 to 4, further comprising a step of measuring a mold or a preform material during the step of arranging. A molding apparatus in which a preform material is disposed between a cylindrical body mold and an upper and lower molds disposed therein, and the upper and lower molds and the preform material are heated to move the upper and lower molds to press the optical element. An optical element molding apparatus comprising means for measuring a mold height before placing a preform material. A molding apparatus in which a preform material is disposed between a cylindrical body mold and an upper and lower molds disposed therein, and the upper and lower molds and the preform material are heated to move the upper and lower molds to press the optical element. An optical element molding apparatus comprising means for measuring the height and size of the preform material when the preform material is placed in the mold. A molding apparatus in which a preform material is disposed between a cylindrical body mold and an upper and lower molds disposed therein, and the upper and lower molds and the preform material are heated to move the upper and lower molds to press the optical element. That is, there is provided means for measuring the height of the mold before placing the preform material and means for measuring the height and size of the preform material when the preform material is placed in the mold. An optical element molding apparatus. 10. The optical element molding method according to claim 7, wherein the mold and the preform material measuring means are non-contact measuring means. A molding apparatus in which a preform material is disposed between a cylindrical body mold and an upper and lower molds disposed therein, and the upper and lower molds and the preform material are heated to move the upper and lower molds to press the optical element. An optical element molding apparatus characterized in that a plurality of lower molds are provided for one upper mold, and these lower molds have a carrier function for transporting preform materials and optical elements after pressing. . A plurality of lower molds are provided for one upper mold, these lower molds have a carrier function to transport preform materials and pressed optical elements, and preform materials are placed on the lower mold offline or in-line. The optical element molding apparatus according to any one of claims 7 to 10, further comprising a measuring means for measuring a mold and a preform material during the step of performing.

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