JP2006110882A - Method for producing complex type optical element and complex type optical element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a complex type optical element having a desired shape which improves productivity in replica molding, reduces costs, and satisfies sufficient optical functions. <P>SOLUTION: In a method for producing a complex type optical element, a photo-curable resin is dropped on the surface of a mold having an optically and structurally desirable shape, pressed/packed by a plane or curved surface lens blank, and irradiated with light. After an interface angle forming means making an angle θ which is formed by the surface of the packed/cured resin on the periphery of the interface between the packed/cured resin generating interfacial peeling during demolding and the mold and expressed on the packed/cured resin side larger than 90° and smaller than 180°, the optical element is demolded. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a so-called replica molding method for obtaining a desired optical surface shape by transferring a molding surface to a photocurable resin by a molding die, and a composite optical element according to a composite optical element formed using the same. The present invention relates to a manufacturing method and a composite optical element.

  Conventionally, as one of the molding technologies for composite optical elements such as aspherical lenses and diffractive optical elements, it is characterized by excellent large-area moldability and high transferability, and is suitable for mass production due to its ease of molding technology. There is replica molding technology. In this replica molding technique, a photocurable resin is dropped onto a mold surface having a reversal shape of a desired optical shape, and a lens blank is crimped and spread out from the mold surface. Is performed by curing the photocurable resin and releasing the cured resin together with the lens blank.

  In the mold release of the replica molding, a part of the cured resin adheres to the surface of the mold, or the optical fine shape such as the diffractive optical element is deformed or damaged by the stress at the time of mold release. It is difficult to release the molded product easily and accurately.

  In the replica molding method for molding a composite optical element having a desired shape, many replica mold release methods have been proposed for the purpose of obtaining a highly accurate molded product with improved transferability and excellent transferability. .

  As a prior proposal for the subject, application of a release agent to a mold surface or addition of a release agent to a resin material, which is a general technique, is already known.

  As a precedent proposal for the subject of the present invention, in Patent Document 1, light having an intensity distribution corresponding to the uneven thickness of the resin layer is irradiated, and a pressure corresponding to a change in the polymerization rate is applied to the resin from the mold. A method for improving transferability has been proposed. Further, in Patent Document 2, the mold and the lens substrate are parallel to the optical axis so as to cancel the deformation amount of the lens base material at the position where the deformation amount of the lens base material due to the curing shrinkage of the molding resin is the largest. There has been proposed a method of reducing the deformation of the optical element due to curing shrinkage of the resin by being relatively close to the substrate. In Patent Document 3, the angle θ between the outer periphery of the mold optical effective diameter and the mold center axis in contact with the end of the wetted resin is 15 ° <θ <45 °, so that the contact angle and the surface tension A method has been proposed in which the shape of the wetted resin end is controlled to release from the outer peripheral portion without any defects. Moreover, in patent document 4, the radiation shrinkage | radiation is irradiated through the masking outside the optical effective diameter on a lens blank, and the cure shrinkage of resin of a non-mask part is supplemented and supplied from the uncured resin of this mask part. Thus, a method for improving the transferability of a molded product has been proposed.

However, in the following patent documents, not only the process configuration and its purpose are different, but also the following problems occur when more precise release properties and efficient productivity are required.
JP-A-6-304936 JP-A-8-99367 Japanese Unexamined Patent Publication No. 7-68569 JP-A-6-75106

  In the mold release process of the replica molding technology for composite optical elements such as aspherical lenses and diffractive optical elements, it is difficult to avoid any deformation or loss of the optical shape due to stress at the time of mold release.

  In the mold release mechanism of replica molding, an interface crack is generated by concentrating a load perpendicular to the mold surface at the outer peripheral edge of the interface between the molding resin and the mold, and this interface crack is transferred to the inner molding surface. The mold release is performed by making it continuously proceed. The smaller the release stress applied to the interface during this release process, the better. Especially when a large release stress is applied, an optical curved surface in an aspheric lens or a grating surface in a diffractive optical element. Give deformation or deficiency. Needless to say, these deformed portions and missing portions significantly deteriorate the optical performance of the composite optical element.

  However, as one of the general patent documents for avoiding this obstacle, a method of reducing the adhesion between the mold and the cured resin by applying a release agent on the mold surface can be raised. The optical curved surface and the fine shape on the surface of the molding die processed extremely precisely are distorted due to liquid dripping or non-uniformity of the film thickness due to surface tension.

  On the other hand, in the method of adding a release agent to the resin material itself, effects such as deterioration of the environmental resistance of the resin material and a decrease in refractive index are observed, which is not preferable as an optical material for molding a composite optical element.

  However, in Patent Document 1 for the purpose of improving the transferability of the molding resin in replica molding, not only the process configuration such as pressure load is different, but also the mold release by controlling the shape of the outer peripheral end of the filling resin. The effect of improving the performance is not given sufficiently. Furthermore, it is difficult to develop applications for resin materials in which the polymerization rate change and the curing shrinkage force do not match. Further, in Patent Document 2 for the purpose of reducing the deformation of the optical element due to the curing shrinkage of the resin in replica molding, not only the process configuration is different, but also the mold release is performed by controlling the shape of the outer peripheral end of the filled resin. The effect of improving the performance is not given sufficiently. Moreover, in the said patent document 3 aiming at the improvement of the mold release property in replica shaping | molding, although it aims at the effect similar to this invention, not only a process structure and the structure of a shaping | molding die but the outer periphery of filling resin Proposal of shape control contrary to the present invention in which the end is made concave is proposed. In Patent Document 4 for the purpose of improving the transferability of a replica molded product, not only the process configuration and purpose such as light irradiation are different, but also the mold release by controlling the shape of the outer peripheral end of the filled resin. The effect of improving the performance is not given sufficiently.

  Furthermore, in these above-mentioned patent documents, since the shape control of the outer peripheral end portion of the filling resin according to the present invention is not performed or is insufficient, onto the mold surface caused by the cohesive failure of the cured resin at the time of mold release. Many resin residues occur. If this phenomenon occurs at the production site, the operator must wipe off the residual resin adhering to the mold surface every time, which not only reduces productivity and increases costs, but also increases the durability of the mold. The nature is also lowered. It goes without saying that a composite optical element that has been released due to large cohesive failure results in a defective product.

  Therefore, in the present invention, without using the above-described method example, the filling cured resin surface at the outer peripheral portion of the interface composed of the filling cured resin and the mold that generates interface peeling at the time of releasing the replica molding is molded. By using an interface angle forming means that makes the angle θ represented by the filling cured resin side of the mold surface 90 ° <θ <180 °, an initial crack at the time of mold release is generated with a small force, and the mold release It improves the performance.

  Accordingly, an object of the present invention is to obtain a composite optical element having a desired shape that improves productivity in replica molding, reduces costs, and satisfies a sufficient optical function.

  The invention of claim 1 for solving the above-mentioned problem is that a photocurable resin is dropped on a molding die surface having an optically desired and mechanically desired optical shape, and the photocurable resin is flattened or curved. In a manufacturing technology for manufacturing a composite optical element by press-filling with a lens blank and irradiating with light, the filled cured resin surface at the outer peripheral portion of the interface composed of a filled cured resin and a mold that generates interface peeling at the time of mold release The composite optical element is released after the interface angle forming means in which the angle θ expressed on the side of the filled cured resin that forms the mold surface is 90 ° <θ <180 ° It is a manufacturing method.

  The invention of claim 2 is compared with the curing shrinkage force of the resin continuously generated inside the resin at the time of photocuring by light irradiation to the photocurable resin filled between the lens blank and the mold. 2. The method of manufacturing a composite optical element according to claim 1, wherein an internal stress always larger than the curing shrinkage force is continuously applied by a pressing means to the photocurable resin by a lens blank or a mold. It is.

  According to the invention of claim 3, a light-shielding body is installed between the outside of the optical effective diameter on the mold surface press-filled with a photocurable resin by a lens blank and the light-curing light source, and uncured filling by the light-shielding body. In the boundary condition between the light shielding portion and the non-light shielding portion of the resin, the angle θ represented on the side of the filling resin to be cured that the filling resin surface cured by the incident curing light and the molding die surface is 90 ° <θ <180 °. The method of manufacturing a composite optical element according to claim 1.

  A fourth aspect of the present invention is a composite optical element manufactured using the manufacturing method according to any one of the first to third aspects.

[Action]
By using the configuration of the first aspect, the following operation is obtained.

  1 and 2 are schematic views showing a curing process of a photocurable resin in replica molding. The outer peripheral end portion in contact with the atmosphere of the pre-curing photocurable resin 2 that is press-filled between the mold 1 and the lens blank 3 is an outer surface as shown in 4 in an uncured state immediately after light irradiation before filling. A convex shape that faces the surface is formed. The convex shape of the outer peripheral end is a surface state such as the water repellency of the mold 1 or the lens blank 3, or the viscoelasticity of the photo-curing resin 2 before curing used, and changes with time due to gravity or ambient temperature. It is formed according to conditions.

  Further, by irradiating the light curable resin 2 before curing with the light of the light curing light source 5, the outer peripheral end portion in contact with the atmosphere of the cured photocurable resin 2 ′ is shown in 4 ′ of FIG. 2. Form an inwardly concave shape as shown. This is because the curing shrinkage represented by the arrow (↑) shown in the cured photocurable resin 2 ′ is relatively high in interfacial energy, and the cured photocurable resin 2 and the mold 1 or the lens blank. 3 is generated at the interface between the photo-curing resin 2 and the atmosphere before curing with a relatively low interface energy. In the curing process shown here, the lens blank 3 is held at equal intervals with respect to the mold 1 by the lens blank holding member 7, but is cured at the interface between the photocurable resin 2 and the mold 1 before curing. If the contraction works, it occurs as a peeling phenomenon of the interface called so-called sink. On the other hand, curing shrinkage that occurs at the interface between the photocurable resin 2 and the lens blank 3 before curing occurs as distortion of the lens blank 3, but the distortion decreases as the lens blank 3 is thicker or its elasticity is smaller. .

  3, 4, and 5 are schematic views showing a mold release process of the composite optical element in replica molding. Each figure shows the filling that the filled cured resin surface 4 ′ at the outer peripheral portion of the interface composed of the filled cured photocurable resin 2 ′ and the mold 1 that causes interface peeling at the time of mold release and the mold surface. The cross section of 0 ° <θ <90 °, θ = 90 °, 90 ° <θ <180 ° of the angle θ expressed on the cured resin side is shown.

FIG. 3 is a cross section in which the filled cured resin surface 4 ′ is formed in a concave shape facing inward (0 ° <θ <90 °), and the release force F shown in the figure is applied to the end of the lens blank 3. The progress of the release crack when the load is applied vertically is indicated by a broken line arrow 6 in the figure. The stress distribution applied to the concave filling resin surface 4 ′ by the releasing force F is the starting point of the release crack progression 6 slightly away from the interface between the mold 1 and the cured photocurable resin 2 ′. The stress is about three times as large as that of the central portion of the concave shape of the filled cured resin surface 4 ′. Specifically, as shown in FIG. 6, in the photocurable resin 2 ′ after curing in which the filling cured resin surface 4 ′ is formed in a concave shape with a curvature radius of 25 μm with a film thickness of 50 μm, the lens blank 3 When a release force of 1.0 [N / mm ² ] in the vertical direction is applied to the end, 15 μm in the horizontal direction and 4 μm in the vertical direction from the contact interface between the filled cured resin surface 4 ′ and the mold 1. Stress concentration was confirmed. This indicates that there is a high possibility of cohesive failure of the resin, in which the release crack occurs on the filled cured resin surface 4 ′ rather than the contact interface between the filled cured resin surface 4 ′ and the mold 1. In the cohesive failure of the filled photocurable resin 2 ′ after curing, not only a larger mold release force is required at the time of mold release, but also a residual resin is left on the mold 1.

  FIG. 4 is a cross section in which the filling cured resin surface 4 ′ forms a vertical surface with respect to the mold 1 (θ = 90 °), and the release force F shown in the figure is applied to the end of the lens blank 3. The progress of the release crack when the load is applied vertically is indicated by a broken line arrow 6 in the figure. The stress distribution applied to the vertical filling cured resin surface 4 ′ by the release force F is the largest at the interface between the mold 1 and the filling cured resin surface 4 ′. Compared to this, approximately twice as much stress is applied. This indicates that there is a high possibility that a release crack will occur at the contact interface between the mold 1 and the filled cured resin surface 4 '. In the interface fracture between the mold 1 and the filled cured resin surface 4 ′, a large release force is not required at the time of mold release, and no residual resin is left on the mold 1.

  FIG. 5 is a cross section in which the filling cured resin surface 4 ′ forms a convex shape facing outward (90 ° <θ <180 °), and the release force F shown in the figure is applied to the end of the lens blank 3. The progress of the release crack when the load is applied vertically is indicated by a broken line arrow 6 in the figure. The stress distribution applied to the convex filling cured resin surface 4 ′ by the mold release force F is greatest at the interface between the mold 1 and the filling cured resin surface 4 ′, and the convex central portion of the filling cured resin surface 4 ′. Compared with that of the above, stress of about 5 times or more is concentrated. This indicates that there is a higher possibility that a release crack will occur at the contact interface between the mold 1 and the filled cured resin surface 4 '. In the interface fracture between the mold 1 and the filled cured resin surface 4 ′, a large release force is not required at the time of mold release, and no residual resin is left on the mold 1. Furthermore, unlike the mold release process in which the vertical surface of FIG. 4 showing a relatively uniform stress distribution on the filled cured resin surface 4 ′ is formed, the mold release stress is applied between the mold 1 and the filled cured resin surface 4 ′. Since it can concentrate on the interface, it can be released more efficiently with less stress. The above results were obtained through simulations of experiments and structural analysis.

  Moreover, in each mold release process shown by FIG.3, FIG.4, FIG.5, since both interfaces with the photocurable resin 2 'after hardening filled with the shaping | molding die 1 and the lens blank 3 have a vertical symmetry. The stress distribution applied to the photocurable resin 2 ′ after the curing is also vertically symmetric with respect to the center line of the resin. However, regarding the interface between the lens blank 3 and the cured photocurable resin 2 ′, the same stress is applied to the interface between the mold 1 and the cured photocurable resin 2 ′. No cracking occurs because of the adhesion treatment.

  Further, by using the configuration of the second aspect, the following operation is obtained.

  FIG. 11 is generated inside the photo-curing resin 2 ′ after curing when the lens blank 3 is held at equal intervals by the lens blank holding member 7 in FIG. 2 described above. This is a measurement of the curing shrinkage force (the force by which the cured photocurable resin 2 ′ that cures and shrinks attracts the mold 1 and the lens blank 3) for each light irradiation amount. It can be seen that curing shrinkage occurs abruptly in the early stage of light irradiation, and converges to a certain value as polymerization hardening of the photocurable resin 2 ′ after curing by light irradiation proceeds. The lens blank 3 at this time is distorted into a concave shape by the curing shrinkage force f of the cured photocurable resin 2 'as shown in FIG.

  Here, as shown in FIG. 13, when the same force f is applied to the lens blank 3 in the same direction in synchronization with the curing shrinkage force f of the cured photocurable resin 2 ′, the filled cured resin surface 4 'Does not change equally to the filled uncured resin surface 4. This is because the curing shrinkage of the cured photocurable resin 2 ′ balances with the internal stress of the resin loaded by pressing the lens blank 3.

  Furthermore, as shown in FIG. 14, when a larger force f ′ is applied to the lens blank 3 in the same direction as the curing shrinkage force f of the cured photocurable resin 2 ′, the filled cured resin surface 4 ′. Forms a convex shape protruding outward from the filled uncured resin surface 4. This is because the internal stress of the resin loaded by pressing the lens blank 3 with the force f ′ exceeds the curing contraction force f of the cured photocurable resin 2 ′, and the stress difference (f′− This is because f) extruded the filling cured resin surface 4 ′.

  Further, by using the configuration of the third aspect, the following operation is obtained.

  FIG. 15 shows a photocurable resin before curing, in which the illustrated light beam 10 is incident on the photocurable resin 2 filled between the mold 1 and the lens blank 3 through a light shield 9. 2 illustrates the curing process. At this time, the cured photocurable resin 2 ′ and the uncured photocurable resin 2 are divided by a filled cured resin surface 4 ′ at the boundary indicated by the angle θ shown in the drawing.

  Therefore, by effectively utilizing the above-mentioned contact interface and interface mold release action, and applying it in the examples shown below, the initial crack at the time of mold release is generated with a small force and the mold release property is improved. The purpose is to let you.

  The effects of the invention described in claims 1, 2, 3, and 4 of the present application can improve the releasability of the composite optical element in replica molding.

  Hereinafter, the best mode for carrying out the present invention will be described in detail with reference to examples.

  7 and 10 are schematic configuration diagrams showing Example 1 in the replica molding apparatus of the present invention. Reference numeral 1 denotes a molding die provided with a reversal shape 8 of a desired optical function shape on its molding surface. The molding die 1 is fixed, and the lens blank 3 is fitted into a ring-shaped lens blank holding member 7 into which the molding die 1 is fitted, and the center axis of the lens blank 3 and the center of the molding surface of the molding die 1. The alignment with the shaft is realized by fitting the lens blank 3 into the fitting portion of the lens blank holding member 7. The lens blank 3 is made of a glass material, and has a flat surface or a curved surface on the optical surface. The ring-shaped lens blank holding member 7 is held in a vertically movable manner, and includes a hydraulic mechanism that can apply a load of 0 to 300 [kgf] in the vertical direction. On the molding surface of the mold 1, a photo-curing resin 2 before curing is supplied by a dispenser (not shown), and a light source 5 for photo-curing is disposed above the lens blank 3 with respect to the optical function surface of the mold. Are installed so as to be incident vertically. As the photocurable resin 2 before curing, an optical resin such as an acrylate, methacrylate, or epoxy whose polymerization is started with a peak at a wavelength of around 365 nm is used, and the photocuring light source 5 is a high-pressure mercury lamp or A light source having an oscillation peak in the vicinity of a wavelength of 365 nm such as an ultra high pressure mercury lamp is used.

  FIG. 8 shows a top view and a side view of the mold 1 in this embodiment. The fine shape forming the optical functional surface 8 has a blazed diffraction grating having a grating height of 5 to 20 μm and a grating width of 0.1 to 3 mm on a plane at an optical effective diameter of 20 mm, as shown in the top view. Concentric with a convex shape toward the center.

  FIG. 9 shows a diffractive optical element ideally produced by the mold 1. The optical functional surface 8 'of the resin layer formed on the lens blank 3 is formed concentrically as a concave shape toward the center of the blazed diffraction grating, that is, as an inverted shape of the mold.

Hereinafter, the molding process in the present embodiment will be described with reference to FIGS. First, an appropriate amount of photo-curing resin 2 before curing is supplied to the vicinity of the center of the molding surface of the molding die 1 with a dispenser (not shown), and a lens that has been subjected to a coupling process on one side in advance to increase the adhesion with the resin in advance. The blank 3 is fitted into the ring-shaped lens blank holding member 7 with the coupling processing surface facing down. At this time, a mechanism for holding the lens blank 3, such as a centering chuck or a bell clamp system, may be provided. Thereafter, the ring-shaped lens blank holding member 7 is lowered by a hydraulic mechanism to bring the mold 1 and the lens blank 3 relatively close to each other, and 5.0 [kgf] relative to the photocurable resin 2 before curing. Apply a constant load. Further, at the moment when the pre-curing photo-curable resin 2 that is pressed by the constant load is filled up to the outer peripheral portion outside the optical effective diameter with a desired thickness, 30 [ The photocurable resin 2 before curing is cured by performing light irradiation of [mW / cm ² ]. At this time, in order to prevent air bubbles from being mixed into the photocurable resin 2 before curing and resin unfilling into the optically effective shape on the mold, the optical properties are considered in consideration of the viscosity of the resin and the wettability of the molding surface. It may be a discontinuous load process in which the constant load applied when filling the resin within the diameter is 0.1 [kgf] and the constant load applied when filling the resin outside the optical effective diameter is 5.0 [kgf]. . Furthermore, the photocurable resin 2 before curing is completely cured by being irradiated for 10 minutes by a light curing light source 5 of 30 [mW / cm ² ]. Thereafter, the ring-shaped lens blank holding member 7 is raised, and the diffractive optical element composed of the cured photocurable resin 2 ′ and the lens blank 3 is peeled off from the mold 1.

  As described above in the operation of the present invention, in this embodiment, the lens blank 3 is pressed by a constant load of 5.0 [kgf], which surpasses the curing shrinkage force of the cured photocurable resin 2 ′. An internal stress was applied to the cured photocurable resin 2 ′ to form a convex shape with the filled cured resin surface 4 ′ protruding outward. At this time, the angle θ represented on the side of the filling and curing resin that the filling and curing resin surface 4 ′ at the outer peripheral portion of the interface composed of the filling and curing resin and the mold that generates the interface peeling at the time of mold release is the following: 90 ° <θ <180 °. Furthermore, as described above in the operation of the present invention, in the mold release process of the present embodiment, the mold release stress can be concentrated on the obtained angle θ (90 ° <θ <180 °), so that it is more efficient. The mold could be released with a small force.

  Therefore, in the configuration of the present embodiment, the filling cured resin surface 4 'of the diffractive optical element is formed to improve the releasability. Accordingly, an object of the present invention is to obtain a diffractive optical element having a desired shape that improves productivity in replica molding, reduces costs, and satisfies a sufficient optical function.

  16, FIG. 17, and FIG. 18 are schematic configuration diagrams showing Embodiment 2 in the replica molding apparatus of the present invention. Reference numeral 1 denotes a molding die provided with a reversal shape 8 of a desired optical function shape on its molding surface. The molding die 1 is fixed, and the lens blank 3 is fitted into a ring-shaped lens blank holding member 7 into which the molding die 1 is fitted, and the center axis of the lens blank 3 and the center of the molding surface of the molding die 1. The alignment with the shaft is realized by fitting the lens blank 3 into the fitting portion of the lens blank holding member 7. The lens blank 3 is made of an optical plastic material and has a curved surface and a flat surface on the optical surface. The ring-shaped lens blank holding member 7 is held so as to be movable up and down, and has a release member 11 for releasing. On the molding surface of the mold 1, a photocurable resin 2 before curing is supplied by a dispenser (not shown), and a light source 5 for photocuring is obliquely above the lens blank 3 with respect to the optical function surface of the mold. It is installed so that ultraviolet rays are incident obliquely. As the photocurable resin 2 before curing, an optical resin such as an acrylate, methacrylate, or epoxy whose polymerization is started with a peak at a wavelength of around 365 nm is used, and the photocuring light source 5 is a high-pressure mercury lamp or A light source having an oscillation peak in the vicinity of a wavelength of 365 nm such as an ultra high pressure mercury lamp is used.

  FIG. 19 shows a top view and a side view of the mold 1 of φ64 mm (optical effective diameter φ54 mm) and radius of curvature R = 77 mm in this example.

  FIG. 20 shows a spherical lens ideally produced by the mold 1. The optical functional surface 8 ′ of the resin layer formed on the lens blank 3 is formed as φ60 mm (optical effective diameter φ54 mm), film thickness up to 200 μm, curvature radius R = 77 mm, that is, as an inverted shape of the mold.

  Hereinafter, the molding process in this example will be described with reference to FIGS. 16, 17, and 18. First, an appropriate amount of photo-curing resin 2 before curing is supplied to the vicinity of the center of the molding surface of the molding die 1 with a dispenser (not shown), and a lens that has been subjected to a coupling process on one side in advance to increase the adhesion with the resin in advance. The blank 3 is fitted into the ring-shaped lens blank holding member 7 with the coupling processing surface facing down. At this time, a mechanism for holding the lens blank 3, such as a centering chuck or a bell clamp system, may be provided. Thereafter, the ring-shaped lens blank holding member 7 is lowered, the mold 1 and the lens blank 3 are relatively brought close to each other, and the uncured photocurable resin 2 is filled to a desired thickness and an outer periphery outside the optical effective diameter. To fill. At this time, the liquid contact speed is adjusted in consideration of the viscosity of the resin and the wettability of the mold molding surface in order to prevent air bubbles from being mixed into the photocurable resin 2 before curing and the resin not filling the mold molding shape. Must.

Thereafter, the light-shielding body 9 cut out from a rubber plate having a thickness of 1 mm as shown in the top view of FIG. 21 is accurately placed on the outer peripheral portion outside the optical effective diameter on the lens blank 3, and the light curing light source 5. 150 [mW / cm ² ] of ultraviolet light is irradiated for 4 minutes so as to be incident at an angle of 40 ° with respect to the optical axis. Here, as shown in FIG. 18, the incident light 10 on the boundary between the light shielding portion and the non-light shielding portion is repeatedly refracted at each interface between the atmosphere, the lens blank 3 and the photocurable resin 2 before curing. However, it is incident at an angle of 35 ° with respect to the optical axis on the molding surface of φ56 mm outside the effective optical diameter. At this time, on the molding surface of φ56 mm, the angle θ represented by the filled cured resin side 4 ′ that the incident light makes with the molding surface is approximately 93 °. In the present embodiment, the material of the light shield 9 is a rubber plate, but the material is not limited to this as long as the material does not damage the lens blank 3 and does not transmit the curing light. Further, after the polymerization and curing of the photocurable resin 2 before curing by light irradiation is completed, the mold 1 is lifted by raising the release member 11 provided in the ring-shaped lens blank holding member 7. The composite optical element composed of the photo-curing resin 2 ′ and the lens blank 3 after curing is peeled off. Furthermore, about the process of the photocurable resin 2 'after hardening and the photocurable resin 2 before hardening adhering to the lens blank 3, it is the said hardening by wiping off or irradiating an ultraviolet-ray again. The previous photocurable resin 2 is cured.

  As described above in the operation of the present invention, in this embodiment, the photocurable resin 2 before curing and the photocuring after curing in the photocurable resin by the incident light 10 by the light irradiation through the light shield 9. An interface with the conductive resin 2 ′ was formed. At this time, the angle θ represented on the side of the filling and curing resin that the filling and curing resin surface 4 ′ at the outer peripheral portion of the interface composed of the filling and curing resin and the mold that generates the interface peeling at the time of mold release is the following: 90 ° <θ <180 °. Furthermore, as described above in the operation of the present invention, in the mold release process of the present embodiment, the mold release stress can be concentrated on the obtained angle θ (90 ° <θ <180 °), so that it is more efficient. The mold could be released with a small force.

  Therefore, in the configuration of the present embodiment, the filling and curing resin surface 4 'of the composite optical element is formed to improve the releasability. Accordingly, an object of the present invention is to obtain a composite optical element having a desired shape that improves productivity in replica molding, reduces costs, and satisfies a sufficient optical function.

It is a figure explaining the effect | action of the hardening process of this invention. It is a figure explaining the effect | action of the hardening process of this invention. It is a figure explaining the effect | action of the mold release process of this invention. It is a figure explaining the effect | action of the mold release process of this invention. It is a figure explaining the effect | action of the mold release process of this invention. It is a figure explaining the effect | action of the mold release process of this invention. It is sectional drawing of the shaping | molding die which shows Example 1 of this invention, and a shaping | molding apparatus. It is sectional drawing and the top view of the shaping | molding die which show Example 1 of this invention. It is sectional drawing and the top view of an optical element which show Example 1 of this invention. It is sectional drawing of the shaping | molding die which shows Example 1 of this invention, and a shaping | molding apparatus. It is a graph explaining the effect | action of the hardening process of this invention. It is a figure explaining the effect | action of the hardening process of this invention. It is a figure explaining the effect | action of the hardening process of this invention. It is a figure explaining the effect | action of the hardening process of this invention. It is a figure explaining the effect | action of the hardening process of this invention. It is sectional drawing of the shaping | molding die which shows Example 2 of this invention, and a shaping | molding apparatus. It is sectional drawing of the shaping | molding die which shows Example 2 of this invention, and a shaping | molding apparatus. It is sectional drawing of the shaping | molding die which shows Example 2 of this invention, and a shaping | molding apparatus. It is sectional drawing and the top view of the shaping | molding die which show Example 2 of this invention. It is sectional drawing and the top view of an optical element which show Example 2 of this invention. It is a top view of the light-shielding body which shows Example 2 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Mold 2 Photocurable resin before hardening 2 'Photocurable resin after hardening 3 Lens blank 4 Filling uncured resin surface 4' Filling cured resin surface 5 Light source 6 Crack progress of mold release 7 Lens blank holding member 8 Molding Optical functional surface of mold 8 'Optical functional surface of optical element 9 Light shield 10 Incident light from light source 11 Push-up member for mold release

Claims (4)

  A compound type optical system is formed by dropping a photocurable resin onto a mold surface having an optical shape that is optically desired and mechanically desired, press-filling the photocurable resin with a flat or curved lens blank, and irradiating with light. In the manufacturing technology for manufacturing the element, the angle θ expressed on the side of the filled curable resin formed by the surface of the filled curable resin at the outer periphery of the interface formed by the filled curable resin and the mold that causes interface peeling at the time of mold release. The composite optical element is released after the means for forming the interface angle such that the angle is 90 ° <θ <180 °.   The means for forming the interface angle is compared with the curing shrinkage force of the resin continuously generated in the resin during photocuring by light irradiation to the photocurable resin filled between the lens blank and the mold. 2. The composite optical element according to claim 1, wherein an internal stress always larger than the curing shrinkage force is continuously applied by a pressing means to the photocurable resin by a lens blank or a mold. Method.   The means for forming the interface angle includes a light-shielding body placed between the outside of the optical effective diameter on the mold surface press-filled with a photocurable resin by a lens blank and a light source for photocuring, and uncured by the light-shielding body. In the boundary condition between the light shielding portion and the non-light shielding portion of the filling resin, the angle θ represented on the side of the filling resin to be cured, which is formed by the filling resin surface cured by the incident curing light, is 90 ° <θ <180 °. The method of manufacturing a composite optical element according to claim 1.   A composite optical element manufactured using the manufacturing method according to claim 1.

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