JP2004077981A - Method for manufacturing small optical element, small optical element, display element having small optical element, display device, image pickup element and image pickup device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a small optical element which can suppress a defective shape caused by partial stripping from a molding die and can attain higher accuracy and to provide a small optical element, a display element having the small optical element, a display device, an image pickup element and an image pickup device. <P>SOLUTION: In the manufacturing method of small optical element by using the molding die, uniting an optical energy curable resin onto a glass substrate and forming a small optical element or the small optical element, when the height of a small convex part formed by the resin is defined as H1 and the height of a flat part formed by the resin is defined as H2, the small optical element is formed so as to satisfy the relation of H2 > H1/5. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a micro-optical element, a micro-optical element, and a display element, a display device, an imaging device, and an imaging device having the micro-optical element, and particularly to a composite optical element having a fine shape (unevenness) on its surface, for example, It relates to a micro lens, a micro prism, and the like.
[0002]
[Prior art]
Methods of manufacturing an optical element include glass grinding, polishing, precision molding using a mold, injection molding and press molding of a thermoplastic resin, and the like, which is used depending on the function, cost, required accuracy, and the like. For example, as a spherical lens, an imaging lens used for a camera or the like is manufactured by grinding and polishing glass, which has little performance degradation with respect to environmental fluctuations of temperature and humidity, and is economically advantageous. Is manufactured by precision molding of glass using a mold. Since a lens used for a finder is not required to have excellent imaging performance even in a camera, it is manufactured by injection molding of a resin from the viewpoint of cost.
[0003]
In addition, in the case of an aspherical lens having a diameter of 30 mm or more or an optical element having a fine irregular shape on the surface, a thin layer of a light energy-curable resin is formed on a glass substrate and cured to obtain a desired surface shape. A forming method is used. Large aspherical lenses have poor shape precision in precision molding of glass, and if the precision is to be ensured, the molding time is long and the cost is high. Optical elements with fine irregularities can not be manufactured because glass will break the irregularities during mold release and cannot be manufactured, and manufacturing with resin is indispensable. The above method reduces the influence.
[0004]
In the molding of the light energy curable resin, since the volume shrinkage accompanying the curing of the resin is as large as 7 to 9%, various adverse effects such as the deterioration of the shape accuracy and the releasability due to the curing shrinkage are caused. . For this reason, Japanese Unexamined Patent Publication No. 2000-2803 discloses that, when molding a microlens, the relationship between the thickness of the thickest portion of the spherical portion and the remaining portion (flat portion) is set within a predetermined range to thereby warp the glass substrate. A method has been proposed for reducing the value of.
[0005]
[Problems to be solved by the invention]
By the way, conventionally, such a molding of a micro optical element using a light energy curable resin is generally performed by forming a concave portion as shown in FIG. 8 as described in JP-A-2000-2803 described above. Using a stamper (molding tool), a light energy-curable resin material is set on the molding tool, a base glass is pressed from above the resin material, and light energy is applied to cure the resin material. The mold is released.
[0006]
However, when a microlens such as that shown in FIG. 1 is molded with a light energy-curable resin using such a mold, if the height H2 of the flat portion is smaller than the height H1 of the spherical portion, the curing shrinkage occurs A part of the spherical portion is peeled off from the mold, and a crater-like shape defect as shown in FIG. 2 is generated, thereby significantly reducing the optical performance. In particular, when used for an imaging lens, it is a fatal defect.
[0007]
In Japanese Patent Application Laid-Open No. 2000-2803, as shown in FIG. 9, when the thickness of the spherical portion is t1 and the remaining portion (flat portion) is t2 in the thickness of the resin layer, 5 ≦ t1 ≦ It is mentioned that the warpage of the glass substrate is reduced by setting the thickness to 30 μm and t2 ≦ 6 μm. However, in order to prevent the occurrence of the crater-like shape defect, a flat portion is formed with respect to the height H1 of the spherical portion. It is not clarified how to specifically determine the height H2.
[0008]
Therefore, the present invention solves the above-mentioned problems, suppresses a shape defect due to partial peeling from a mold, and enables a method of manufacturing a micro optical element capable of achieving high precision. It is another object of the present invention to provide a display device, a display device, an imaging device, and an imaging device having the micro optical element.
[0009]
[Means for Solving the Problems]
The present invention provides a method for manufacturing a micro-optical element configured as described in the following (1) to (10), a micro-optical element, and a display element, a display device, an imaging device, and an imaging device having the micro-optical element. Things.
(1) A method for manufacturing a micro optical element in which a light energy curable resin is integrated on a glass substrate using a molding die to form a micro optical element,
When the height of the minute protrusions formed of the resin is H1, and the height of the flat portion formed of the resin is H2, the height H1 of the minute protrusions and the height H2 of the flat portion are: A method for manufacturing a micro optical element, comprising forming a micro optical element so as to satisfy the following expression.
H2> H1 / 5
(2) The method for manufacturing a micro optical element according to the above (1), wherein the micro optical element is formed such that the height H1 of the micro convex portion satisfies the following expression.
50 μm ≦ H1 ≦ 300 μm
(3) The method for producing a micro optical element according to the above (1) or (2), wherein the micro optical element is a composite optical element.
(4) In a micro optical element formed by a molding die using a light energy curable resin,
Assuming that the height of the minute protrusion formed of the resin is H1 and the height of the flat portion formed of the resin is H2, the height H1 of the minute protrusion and the height H2 of the flat portion are: A micro-optical element characterized by satisfying the following expression:
H2> H1 / 5
(5) The micro optical element according to the above (4), wherein the height H1 of the micro convex portion satisfies the following expression.
50 μm ≦ H1 ≦ 300 μm
(6) The micro optical element according to the above (4) or (5), wherein the micro optical element is a composite optical element.
(7) A micro-optical element manufactured by the method for manufacturing a micro-optical element according to any one of the above (1) to (3), or the micro optical element according to any one of the above (4) to (6). A display element, comprising:
(8) A display device comprising the display element according to (7).
(9) The micro optical element manufactured by the method for manufacturing a micro optical element according to any one of the above (1) to (3) or the micro optical element according to any one of the above (4) to (6) An imaging device, comprising:
(10) An imaging device comprising the imaging device according to (9).
[0010]
BEST MODE FOR CARRYING OUT THE INVENTION
Applying the above configuration, for example, making the height of the flat portion larger than １ ／ times the height of the minute convex portion with respect to the height of the minute convex portion (the height of the spherical portion in the case of the microlens). Thereby, it is possible to release the stress accompanying the curing shrinkage of the minute convex portion to the flat portion, and it is possible to prevent a shape defect due to partial peeling from the mold as shown in FIG. In particular, when the height of the minute projections is larger than 50 μm, this effect is increased. However, when the height of the minute projections is equal to or larger than a predetermined size, the thickness of the flat portion also increases, and the effect is reduced. As a result of various studies by the present inventors, it has been clarified that the effect is large when the height of the minute projections is in the range of 50 μm to 300 μm.
For this reason, in a micro optical element in which a light energy curable resin is molded and cured on a glass substrate using a mold, the height of the resin micro convex portion is H1, and the height of the flat portion is H2. By setting H2> H1 / 5, it is possible to prevent a shape defect at the time of resin curing shrinkage.
In this case, by setting the height of the minute projections in the range of 50 μm to 300 μm, it is possible to further enhance the effect of preventing shape defects.
[0011]
【Example】
Hereinafter, examples of the present invention will be described.
[Example 1]
FIG. 1 is a schematic diagram illustrating a configuration of a microlens according to a first embodiment of the present invention. In FIG. 1, reference numeral 1 denotes a molded light energy curable resin, 1a denotes a spherical portion serving as an optical function portion, 1b denotes a flat portion, and 2 denotes a flat glass substrate.
In the present embodiment, using the above-described method for molding a micro optical element using a general light energy curable resin, the height H1 of the spherical portion of the optical function portion 1a is 170 μm, and the height H2 of the flat portion is 50 μm. A micro lens was formed. According to this, there was no defect in the optical function part and the shape accuracy was good.
[0012]
(Comparative Example 1)
In Comparative Example 1, a microlens was formed using the same method of forming a micro-optical element as in Example 1, except that the height of the flat portion was set to 30 μm with respect to Example 1. According to this, as shown in FIG. 2, a part 3c of the spherical portion was deformed into a crater shape, and required optical performance was not obtained.
[0013]
[Example 2]
FIG. 3 is a schematic diagram illustrating a configuration of a microprism according to the second embodiment of the present invention.
In FIG. 3, reference numeral 5 denotes a molded light energy curable resin, 5a denotes a prism portion serving as an optical function portion, 5b denotes a flat portion, and 6 denotes a flat glass substrate.
In the present embodiment, using the above-described method for molding a micro optical element using a general light energy curable resin, the height H1 of the prism portion of the optical function portion 5a is 250 μm, and the height H2 of the flat portion is 60 μm. A microprism was formed. According to this, there was no defect in the optical function part and the shape accuracy was good.
[0014]
(Comparative Example 2)
In Comparative Example 2, a microprism was formed using the same method of forming a micro optical element as in Example 2, except that the height of the flat portion was set to 50 μm with respect to Example 2. According to this, as shown in FIG. 4, a part 7c of the prism portion was deformed in a crater shape, and required optical performance was not obtained.
[0015]
[Example 3]
FIG. 5 is a schematic diagram illustrating a configuration of a micro optical element according to Embodiment 3 of the present invention. In FIG. 5, reference numeral 9 denotes a molded light energy curable resin, 9a denotes a lattice portion serving as an optical function portion, 9b denotes a flat portion, and 10 denotes a flat glass substrate.
In the present embodiment, the method of molding a micro optical element using the above-mentioned general light energy curable resin is used, and the height H1 of the grating portion 9a, which is the optical function portion, is 20 μm, and the height H2 of the flat portion is 7 μm. A micro optical element was formed. According to this, there was no defect in the optical function part and the shape accuracy was good.
[0016]
(Comparative Example 3)
In Comparative Example 3, a micro-optical element was formed using the same method for forming a micro-optical element as in Example 3, except that the height of the flat portion was 4 μm. According to this, as shown in FIG. 6, a part 11c of the side surface of the grating portion was deformed into a crater shape, and required optical performance was not obtained.
[0017]
[Example 4]
FIG. 7 is a schematic diagram illustrating a configuration of a micro optical element according to Embodiment 4 of the present invention. In FIG. 7, reference numeral 13 denotes a molded light energy curable resin, 13a denotes a spherical portion serving as an optical function portion, 13b denotes a flat portion, and 14 denotes a spherical glass substrate.
In the present embodiment, using the above-described method for molding a micro optical element using a general light energy curable resin, the height H1 of the spherical portion of the optical function portion 13a is 200 μm, and the height H2 of the flat portion is 50 μm. A micro optical element was formed. According to this, there was no defect in the optical function part and the shape accuracy was good.
[0018]
(Comparative Example 4)
In Comparative Example 4, a micro-optical element was molded using the same method for molding a micro-optical element as in Example 4, except that the height of the flat portion was set to 40 μm with respect to Example 4. According to this, a part of the spherical portion was deformed in a crater shape, and required optical performance could not be obtained.
[0019]
As is clear from the results of the above Examples and Comparative Examples, by setting the height of the flat portion to be larger than １ ／ times the height of the spherical portion, defects due to mold release failure during curing shrinkage are prevented. be able to. In addition, by using such a minute optical element, a display element, a display device, an imaging device, and an imaging device having excellent optical performance can be configured.
[0020]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the micro optical element which can suppress the shape defect by partial peeling from a shaping | molding die, and can attain high precision, a micro optical element, and the said micro optical element , A display device, an image pickup device, and an image pickup device having the same.
[Brief description of the drawings]
FIG. 1 is a schematic diagram illustrating a configuration of a microlens according to a first embodiment of the present invention.
FIG. 2 is a schematic diagram for explaining a defective state of a sphere in Comparative Example 1.
FIG. 3 is a schematic diagram illustrating a configuration of a microprism according to a second embodiment of the present invention.
FIG. 4 is a schematic diagram for explaining a defective state of a sphere in Comparative Example 2.
FIG. 5 is a schematic diagram illustrating a configuration of a micro optical element according to a third embodiment of the present invention.
FIG. 6 is a schematic diagram for explaining a defective state of a sphere in Comparative Example 3.
FIG. 7 is a schematic diagram illustrating a configuration of a micro optical element according to a fourth embodiment of the present invention.
FIG. 8 is a schematic diagram for explaining a conventional method for forming a micro optical element using a light energy curable resin.
FIG. 9 is a schematic diagram for explaining the relationship between the thickness of the thickest part of the spherical part and the remaining part (flat part) when forming the microlens.
[Explanation of symbols]
1, 3, 5, 7, 9,
11, 13: light energy-curable resin 1a, 13a: spherical portion 1b, 5b, 9b, 13b: flat portion 2, 4, 6, 8,
10, 12, 14: glass substrate 5a: prism portion 9a: grating portion

Claims (10)

In a method for manufacturing a micro-optical element for forming a micro-optical element by integrating a light energy curable resin on a glass substrate using a molding die,
When the height of the minute protrusions formed of the resin is H1, and the height of the flat portion formed of the resin is H2, the height H1 of the minute protrusions and the height H2 of the flat portion are: A method for manufacturing a micro optical element, comprising forming a micro optical element so as to satisfy the following expression.
H2> H1 / 5 The method for manufacturing a micro optical element according to claim 1, wherein the micro optical element is formed such that the height H1 of the micro convex portion satisfies the following expression.
50 μm ≦ H1 ≦ 300 μm The method for manufacturing a micro optical element according to claim 1, wherein the micro optical element is a composite optical element. In a micro optical element formed by a mold using a light energy curing resin,
Assuming that the height of the minute protrusion formed of the resin is H1 and the height of the flat portion formed of the resin is H2, the height H1 of the minute protrusion and the height H2 of the flat portion are: A micro-optical element characterized by satisfying the following expression:
H2> H1 / 5 The micro optical element according to claim 4, wherein the height H1 of the micro convex portion satisfies the following expression.
50 μm ≦ H1 ≦ 300 μm The micro optical element according to claim 4, wherein the micro optical element is a composite optical element. A micro-optical element manufactured by the method for manufacturing a micro-optical element according to any one of claims 1 to 3, or a micro-optical element according to any one of claims 4 to 6. A display element characterized by the above-mentioned. A display device comprising the display element according to claim 7. A micro-optical element manufactured by the method for manufacturing a micro-optical element according to any one of claims 1 to 3, or a micro-optical element according to any one of claims 4 to 6. An imaging device characterized by the above-mentioned. An imaging apparatus comprising the imaging device according to claim 9.

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