CN111103640B - Fresnel lens metal mold manufacturing method - Google Patents
Fresnel lens metal mold manufacturing method Download PDFInfo
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- CN111103640B CN111103640B CN201911183750.6A CN201911183750A CN111103640B CN 111103640 B CN111103640 B CN 111103640B CN 201911183750 A CN201911183750 A CN 201911183750A CN 111103640 B CN111103640 B CN 111103640B
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- fresnel
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- soft template
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B3/00—Simple or compound lenses
- G02B3/0006—Arrays
- G02B3/0012—Arrays characterised by the manufacturing method
- G02B3/0025—Machining, e.g. grinding, polishing, diamond turning, manufacturing of mould parts
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B3/00—Simple or compound lenses
- G02B3/02—Simple or compound lenses with non-spherical faces
- G02B3/08—Simple or compound lenses with non-spherical faces with discontinuous faces, e.g. Fresnel lens
Abstract
The invention provides a Fresnel lens metal mold manufacturing method, which comprises the following steps: step S1, providing a single-cavity female die; step S2, covering the first plastic soft template on a first Fresnel structure groove of the single-hole female die to manufacture a Fresnel soft template; step S3, respectively fixing and installing a plurality of Fresnel soft templates in second plastic soft templates to obtain characteristic soft templates; step S4, conducting treatment is carried out on one side of the characteristic soft template, which is provided with the Fresnel structure, so that a metal layer is formed; and step S5, performing electroforming treatment on the side, provided with the metal layer, of the feature soft template after the electric conduction treatment to form a metal electroforming layer, and demolding the feature soft template and the metal electroforming layer to obtain the Fresnel lens metal mold. Compared with the prior art, the manufacturing method of the Fresnel lens metal mold is low in manufacturing cost and high in machining precision.
Description
[ technical field ] A method for producing a semiconductor device
The invention relates to the field of optical lens manufacturing, in particular to a manufacturing method of a Fresnel lens metal mold.
[ background of the invention ]
In the field of optical lenses, the fresnel lens has good optical performance while having the characteristics of lightness, thin thickness and the like, so that the fresnel lens is widely applied to various optical application scenes. The mold for manufacturing and producing the fresnel lens also becomes a key point of research in the industry, wherein in order to improve the production efficiency of the fresnel lens, a metal mold for manufacturing the fresnel lens with a plurality of fresnel structures is often required.
The manufacturing method of the Fresnel lens metal mold in the related art comprises the following three steps:
firstly, a diamond processing method: processing the metal base material in a diamond turning mode to manufacture a plurality of single-hole Fresnel lens female dies, and splicing the plurality of single-hole Fresnel lens female dies into a whole-plate multi-hole Fresnel lens metal die, but the diamond processing cost is high;
secondly, photoetching: the metal base material is processed by using photoetching equipment to obtain a full-page multi-cavity Fresnel lens metal mold, but the photoetching equipment is expensive, so that the processing cost is high;
thirdly, an electroforming replication method: firstly, a single-cavity Fresnel lens female die is processed, a plurality of single-cavity Fresnel lens female dies are copied by adopting an electroforming copying method, and the plurality of single-cavity Fresnel lens female dies are spliced to obtain a full-page multi-cavity Fresnel lens metal die.
In summary, in the related art, the three methods cannot simultaneously satisfy two conditions of low processing cost and high precision of the metal mold for the fresnel lens with multiple fresnel structures.
Therefore, there is a need to provide a new method for manufacturing a metal mold for a fresnel lens to solve the above-mentioned problems.
[ summary of the invention ]
The invention aims to provide a method for manufacturing a Fresnel lens metal mold with low manufacturing cost and high processing precision.
In order to achieve the above purpose, the present invention provides a method for manufacturing a fresnel lens metal mold, comprising the following steps:
step S1, providing a single-cavity female die; the single-cavity female die comprises a main body part and a first Fresnel structure groove formed in the main body part;
step S2, covering a first plastic soft template on the first Fresnel structure groove of the single-hole female die to manufacture a Fresnel soft template; the Fresnel soft template comprises a Fresnel structure matched with the first Fresnel structure groove;
step S3, respectively fixing and installing the Fresnel soft templates in second plastic soft templates to obtain characteristic soft templates; the second plastic soft template comprises a plurality of limiting tool holes for installing the Fresnel soft template, the limiting tool holes are arranged at intervals, and the limiting tool holes and the Fresnel soft template are arranged in a one-to-one correspondence manner;
step S4, conducting treatment is carried out on one side, provided with the Fresnel structure, of the characteristic soft template to form a metal layer;
step S5, performing electroforming treatment on the side, provided with the metal layer, of the feature soft template after the electric conduction treatment to form a metal electroforming layer, and demolding the feature soft template and the metal electroforming layer to obtain a Fresnel lens metal mold; the Fresnel lens metal mold comprises a plurality of second Fresnel structure grooves which are arranged at intervals, and the second Fresnel structure grooves are matched with the Fresnel structures.
Preferably, the step S2 specifically includes the following sub-steps:
step S21, covering the first plastic soft template on the single-hole female die and completely covering the first Fresnel structure groove;
step S22, heating the single-cavity female die to a first preset temperature to soften the first plastic soft die plate;
step S23, continuously applying pressure to the first plastic soft template within a preset time, so that the first plastic soft template after being heated and softened completely fills the first fresnel structure groove;
step S24, cooling the temperature of the single-cavity female die to a second preset temperature, and taking out the first plastic soft template to obtain the Fresnel soft template; wherein the second preset temperature is less than the first preset temperature.
Preferably, the first preset temperature is between 80 ℃ and 150 ℃; the preset time is 10-30 minutes; the second preset temperature is less than or equal to 50 ℃; the applied pressure was 200N.
Preferably, the step S3 specifically includes: step S31, attaching an electrostatic film to one side of the second plastic soft template;
step S32, respectively placing the Fresnel soft templates in the limiting tool holes, and enabling the Fresnel structure surface of each Fresnel soft template to face the electrostatic film;
step S33, gluing the surfaces of the Fresnel soft templates opposite to the Fresnel structure surfaces of the Fresnel soft templates to fix the Fresnel soft templates and the second plastic soft templates;
and step S34, removing the electrostatic film to obtain the characteristic soft template.
Preferably, the step S32 further includes: and cutting the Fresnel soft template to enable the overall dimension of the Fresnel soft template to be matched with the limiting tool hole.
Preferably, in step S32, when the fresnel soft template is cut, the fresnel structure is located at the center of the fresnel soft template.
Preferably, in step S4, the method of the conductive treatment is an electrodeposition manufacturing process.
Preferably, the first plastic soft template comprises any one of polycarbonate, polyvinyl chloride and organic glass.
Preferably, the second plastic soft template comprises any one of polycarbonate, polyvinyl chloride and organic glass.
Preferably, the thickness of the single-cavity female die is 8mm, and the diameter of the first Fresnel structure groove is 100 mm.
Preferably, the thickness of the first plastic soft template and the thickness of the second plastic soft template are both 1 mm.
Preferably, in step S4, the metal layer is Ni and has a thickness of 100 nm.
Preferably, in the step S5, the metal electroformed layer is Ni having a thickness of less than 500 μm.
Compared with the prior art, the method for manufacturing the Fresnel lens metal mold only needs to process a single-cavity female mold, the single-cavity female mold can be used for continuously manufacturing a plurality of first plastic soft templates into a plurality of Fresnel soft templates respectively, the Fresnel soft templates are fixedly arranged in second plastic soft templates respectively to obtain the characteristic soft templates, the side, provided with the Fresnel structures, of the characteristic soft templates is subjected to electric conduction treatment to form a metal layer, the side, provided with the metal layer, of the characteristic soft templates after the electric conduction treatment is subjected to electric casting treatment to form a metal electric casting layer, the characteristic soft templates and the metal electric casting layer are demolded to obtain the Fresnel lens metal mold, namely, the Fresnel lens metal mold is manufactured in a multi-cavity simultaneous electric casting mode, so that the method can ensure the processing precision, the manufacturing cost is reduced.
[ description of the drawings ]
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without inventive efforts, wherein:
FIG. 1 is a schematic flow chart of a Fresnel lens metal mold manufacturing method according to the present invention;
FIG. 2 is a schematic flowchart of step S2 in FIG. 1;
FIG. 3 is a detailed flowchart of step S3 in FIG. 1;
FIG. 4 is a schematic diagram of the first plastic soft template and the single-cavity female mold of step S21 in FIG. 2;
FIG. 5 is a schematic view of the first plastic soft template of step S22 of FIG. 2 mated with a heated single cavity master;
fig. 6 is a schematic view illustrating the first plastic film board pressed at step S23 in fig. 2;
fig. 7 is a schematic diagram of the fresnel soft template taken out in step S24 in fig. 2;
FIG. 8 is a schematic cross-sectional view of a Fresnel soft template of the present invention;
FIG. 9 is a schematic view of the Fresnel soft template and the second soft template in step S32 of FIG. 3;
FIG. 10 is a schematic cross-sectional view of the Fresnel soft template and the second soft template of FIG. 9;
fig. 11 is a schematic view of the fresnel soft template and the second soft template in step S33 in fig. 3 after being glued;
FIG. 12 is a schematic cross-sectional view of the Fresnel soft template and the second soft template of FIG. 11 after being glued;
FIG. 13 is a schematic structural diagram of the characteristic soft template of step S34 in FIG. 3;
FIG. 14 is a schematic cross-sectional view of the featured soft template of FIG. 13;
FIG. 15 is a schematic view of the metal electroformed layer and the featured soft template of step S5 of FIG. 1;
FIG. 16 is a schematic cross-sectional view of the metal electroformed layer and the featured soft template of FIG. 15;
fig. 17 is a schematic structural view of a fresnel lens metal mold.
[ detailed description ] embodiments
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-17, the present invention provides a method for manufacturing a fresnel lens metal mold, including the following steps:
in step S1, a one-hole master mold 1 is provided.
Specifically, in step S1, the one-cavity master mold 1 includes a main body 11 and a first fresnel-structure groove 10 formed in the main body 11.
In order to ensure the precision of the single-cavity master mold 1, in the present embodiment, a metal substrate is machined into the single-cavity master mold 1 by diamond turning, and in essence, one side of the metal substrate is turned to form a first fresnel structure groove 10 in the main body 11 of the single-cavity master mold 1, and the shape of the first fresnel structure groove 10 is not limited, and may be specifically designed according to the specific structure of the fresnel lens to be actually manufactured.
In order to satisfy the processing conditions of the hot press molding process, the thickness of the single-cavity female die 1 is 5mm to 10mm, and the diameter of the first fresnel structure groove 10 is less than or equal to 200 mm. For example, in the present embodiment, the thickness of the one-cavity master mold 1 is preferably 8mm, and the diameter of the first fresnel-structure groove 10 is preferably 100 mm.
Step S2, covering the first plastic soft template 2 on the first fresnel structure groove 10 of the single-cavity female die 1 to form a fresnel soft template 2 a.
Specifically, in the step S2, the fresnel soft template 2a includes the fresnel structure 21a matched with the first fresnel-structure groove 10.
Further, the step S2 specifically includes the following sub-steps:
step S21, covering the first plastic soft template 2 on the single-cavity female die 1 and completely covering the first fresnel structure groove 10.
Step S22, heating the single-cavity female die 1 to a first preset temperature to soften the first plastic soft template 2; wherein the first preset temperature is between 80 ℃ and 150 ℃.
Step S23, continuously applying pressure to the first plastic soft template 2 by the hot press board 3 within a preset time by the hot press machine, so that the first plastic soft template 2 after being heated and softened completely fills the first fresnel structure groove 10; the preset time is 10-30 minutes, and the preferable pressure applied to the first plastic soft template 2 is 200N.
Step S24, cooling the temperature of the single-cavity female die 1 to a second preset temperature, and taking out the first plastic soft template 2 to obtain the Fresnel soft template 2 a; wherein the second preset temperature is lower than the first preset temperature, and the second preset temperature is lower than or equal to 50 ℃.
After the step S2, the step S3 is preceded by the following preprocessing steps:
cutting the second plastic soft template 4 to form a plurality of limiting tool holes 40 on the second plastic soft template 4;
and cutting the Fresnel soft template 2a to enable the outline dimension of the Fresnel soft template 2a to be matched with the limiting tool hole 40. For example, the fresnel soft template 2a is cut by a laser cutting method or a linear cutting method, so as to ensure that the fresnel structure 21a is located at the geometric center of the fresnel soft template 2 a.
Step S3, the fresnel soft templates 2a are respectively fixed and installed in the second plastic soft template 4 to obtain the characteristic soft template 4 a.
Specifically, in the step S3, the second plastic soft template 4 includes a plurality of limiting tool holes 40 for installing the fresnel soft template 2a, the limiting tool holes 40 are arranged at intervals, and the limiting tool holes 40 are arranged in one-to-one correspondence with the fresnel soft template 2 a.
Further, the step S3 specifically includes the following sub-steps:
and step S31, attaching the electrostatic film 5 to one side of the second plastic soft template 4.
Step S32, placing the plurality of fresnel soft templates 2a in the plurality of limiting tool holes 40, respectively, and making the fresnel structure surface of the fresnel soft templates 2a face the electrostatic film 5, where the fresnel structure surface is used as the front surface of the fresnel soft templates 2 a.
Specifically, the step S32 further includes: cutting the Fresnel soft template 21a to enable the outline dimension of the Fresnel soft template 21a to be matched with the limiting tool hole 40; preferably, in the step S32, when the fresnel soft template 2a is cut, the fresnel structure 21a is located at the center of the fresnel soft template 2a, so that the positioning accuracy of the fresnel structure 21a mounted on the second plastic soft template 4 is effectively ensured.
Step S33, gluing the surfaces of the plurality of fresnel soft templates 2a opposite to the fresnel structure surface, that is, forming a glue layer 6 on one side of the back surface of the fresnel soft template 2a for bonding the fresnel soft template 2a and the second plastic soft template 4, wherein the glue layer 6 fixes the plurality of fresnel soft templates 2a and the second plastic soft template 4.
And step S34, removing the electrostatic film 5 to obtain the characteristic soft template 4 a.
Step S4, conducting the characteristic soft template 4a on the side where the fresnel structure 2a is disposed, to form a metal layer.
Specifically, in step S4, the method of the electrical conduction treatment is an electrodeposition manufacturing process;
further, the thickness of the metal layer is not limited, for example, in the present embodiment, the metal layer is Ni, and the thickness thereof is 100 nm; of course, the thickness of the metal layer can be specifically set according to actual conditions.
Step S5, performing electroforming on the side, where the metal layer is arranged, of the feature soft template 4a after the conductive processing to form a metal electroformed layer 7, and demolding the feature soft template 4a and the metal electroformed layer 7 to obtain a fresnel lens metal mold 7 a; the fresnel lens metal mold 7a includes a plurality of second fresnel structure grooves 71a arranged at intervals, and the second fresnel structure grooves are matched with the fresnel structures.
Specifically, the thickness of the metal electroformed layer 7 is not limited, and in the step S5, the metal electroformed layer 7 is Ni having a thickness of less than 500 μm; of course, the thickness of the metal layer can be specifically set according to actual conditions.
It is worth mentioning that the materials of the first plastic soft template 2 and the second plastic soft template 4 are not limited, and the first plastic soft template 2 and the second plastic soft template 4 are any one of Polycarbonate (PC), polyvinyl chloride (PVC) and organic glass (PMMA), and in this embodiment, the materials of the two are preferably organic glass (PMMA); in addition, the thicknesses of the first plastic soft template 2 and the second plastic soft template 4 are also not limited, and in the present embodiment, the thicknesses of the first plastic soft template 2 and the second plastic soft template 4 are both 1 mm; of course, the material and thickness of the first plastic soft template 2 and the second plastic soft template 4 can be specifically set according to the actual manufacturing requirement.
Compared with the prior art, the method for manufacturing the Fresnel lens metal mold only needs to process a single-cavity female mold, the single-cavity female mold can be used for continuously manufacturing a plurality of first plastic soft templates into a plurality of Fresnel soft templates respectively, the Fresnel soft templates are fixedly arranged in second plastic soft templates respectively to obtain the characteristic soft templates, the side, provided with the Fresnel structures, of the characteristic soft templates is subjected to electric conduction treatment to form a metal layer, the side, provided with the metal layer, of the characteristic soft templates after the electric conduction treatment is subjected to electric casting treatment to form a metal electric casting layer, the characteristic soft templates and the metal electric casting layer are demolded to obtain the Fresnel lens metal mold, namely, the Fresnel lens metal mold is manufactured in a multi-cavity simultaneous electric casting mode, so that the method can ensure the processing precision, the manufacturing cost is reduced.
While the foregoing is directed to embodiments of the present invention, it will be understood by those skilled in the art that various changes may be made without departing from the spirit and scope of the invention.
Claims (12)
1. A Fresnel lens metal mold manufacturing method is characterized by comprising the following steps:
step S1, providing a single-cavity female die; the single-cavity female die comprises a main body part and a first Fresnel structure groove formed in the main body part;
step S2, covering a first plastic soft template on the first Fresnel structure groove of the single-hole female die to manufacture a Fresnel soft template; the Fresnel soft template comprises a Fresnel structure matched with the first Fresnel structure groove;
step S3, respectively fixing and installing the Fresnel soft templates in second plastic soft templates to obtain characteristic soft templates; the second plastic soft template comprises a plurality of limiting tool holes for mounting the Fresnel soft template, the limiting tool holes penetrate through the second plastic soft template, the limiting tool holes are arranged at intervals, and the limiting tool holes and the Fresnel soft template are arranged in a one-to-one correspondence manner; the S3 specifically includes: step S31, attaching an electrostatic film to one side of the second plastic soft template; step S32, respectively placing the Fresnel soft templates in the limiting tool holes, and enabling the Fresnel structure surface of each Fresnel soft template to face the electrostatic film; step S33, gluing the surfaces of the Fresnel soft templates opposite to the Fresnel structure surfaces of the Fresnel soft templates to fix the Fresnel soft templates and the second plastic soft templates; step S34, removing the electrostatic film to obtain the characteristic soft template;
step S4, conducting treatment is carried out on one side, provided with the Fresnel structure, of the characteristic soft template to form a metal layer;
step S5, performing electroforming treatment on the side, provided with the metal layer, of the feature soft template after the electric conduction treatment to form a metal electroforming layer, and demolding the feature soft template and the metal electroforming layer to obtain a Fresnel lens metal mold; the Fresnel lens metal mold comprises a plurality of second Fresnel structure grooves which are arranged at intervals, and the second Fresnel structure grooves are matched with the Fresnel structures.
2. The fresnel lens metal mold manufacturing method according to claim 1, wherein the step S2 specifically includes the following sub-steps:
step S21, covering the first plastic soft template on the single-hole female die and completely covering the first Fresnel structure groove;
step S22, heating the single-cavity female die to a first preset temperature to soften the first plastic soft die plate;
step S23, continuously applying pressure to the first plastic soft template within a preset time, so that the first plastic soft template after being heated and softened completely fills the first fresnel structure groove;
step S24, cooling the temperature of the single-cavity female die to a second preset temperature, and taking out the first plastic soft template to obtain the Fresnel soft template; wherein the second preset temperature is less than the first preset temperature.
3. The fresnel lens metal mold manufacturing method according to claim 2, wherein the first preset temperature is between 80 ℃ and 150 ℃; the preset time is 10-30 minutes; the second preset temperature is less than or equal to 50 ℃; the applied pressure was 200N.
4. The fresnel-lens metal mold manufacturing method according to claim 1, wherein the step S32 further includes: and cutting the Fresnel soft template to enable the overall dimension of the Fresnel soft template to be matched with the limiting tool hole.
5. The method for manufacturing the metal mold for the Fresnel lens according to claim 4, wherein in the step S32, when the soft Fresnel lens template is cut, the Fresnel structure is located at the center of the soft Fresnel lens template.
6. The fresnel lens metal mold manufacturing method according to claim 1, wherein in the step S4, the method of the electrical conduction treatment is an electrodeposition manufacturing process.
7. The fresnel lens metal mold manufacturing method according to claim 1, wherein the first plastic soft mold comprises any one of polycarbonate, polyvinyl chloride, and organic glass.
8. The fresnel lens metal mold manufacturing method according to claim 1, wherein the second plastic soft mold plate comprises any one of polycarbonate, polyvinyl chloride, and organic glass.
9. The method for manufacturing a metal mold for a Fresnel lens according to claim 1, wherein the thickness of the single-cavity female mold is 8mm, and the diameter of the first Fresnel structure groove is 100 mm.
10. The fresnel-lens metal mold manufacturing method according to claim 1, wherein the first plastic soft mold plate and the second plastic soft mold plate each have a thickness of 1 mm.
11. The fresnel-lens metal mold manufacturing method according to claim 1, wherein in the step S4, the metal layer is Ni and has a thickness of 100 nm.
12. The fresnel lens metal mold manufacturing method according to claim 1, wherein in the step S5, the metal electroformed layer is Ni having a thickness of less than 500 μm.
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| CN201911183750.6A CN111103640B (en) | 2019-11-27 | 2019-11-27 | Fresnel lens metal mold manufacturing method |
| PCT/CN2019/124716 WO2021103152A1 (en) | 2019-11-27 | 2019-12-12 | Method for manufacturing fresnel lens metal mold |
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| CN201911183750.6A CN111103640B (en) | 2019-11-27 | 2019-11-27 | Fresnel lens metal mold manufacturing method |
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| CN111796346A (en) * | 2020-07-31 | 2020-10-20 | 苏州诚思数字技术有限公司 | Double-image-proof Fresnel lens and preparation method thereof |
| WO2024022515A1 (en) * | 2022-07-28 | 2024-02-01 | 青岛海信激光显示股份有限公司 | Projection screen, projection system, die and die master |
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| WO2021103152A1 (en) | 2021-06-03 |
| CN111103640A (en) | 2020-05-05 |
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