JP2007008004A - Optical component, manufacturing method of optical component and manufacturing method of mold for optical component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method and the like for optical components and the like, which can achieve forming a fine pitch and form them simply and with good accuracy. <P>SOLUTION: The manufacturing method of the optical components and the like comprises the steps of selectively applying light to a photocurable resin liquid and forming a cured resin layer by repeating exposure while setting the projection area as a unit and laminating the cured resin layer successively to form a three-dimensional shape. The method is especially effective in a case wherein the structure of the optical components and the like is a complex three-dimensional structure having an overhang part. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing an optical component, wherein a photocurable resin liquid is selectively irradiated with light to form a cured resin layer, and the cured resin layer is sequentially laminated to form a three-dimensional structure. The present invention relates to a method for manufacturing an optical component mold, and an optical component manufactured using an optical component mold.

In recent years, projection TVs equipped with an optical engine such as a liquid crystal device and a digital micro device have been rapidly spread. This projection TV is equipped with a transmission screen for observing images.
FIG. 3 is a cross-sectional view showing the configuration of a conventional transmission screen (Patent Document 1). As shown in the figure, the transmission screen 50 includes a Fresnel lens sheet 51, a lenticular lens sheet 52, a front plate 53, a first adhesive layer 54, a second adhesive layer 55, an AR film 56, and the like. The Fresnel lens sheet 51 is for narrowing the image light from the rear projection type projector within a range of a certain angle, and is provided on the light source side. The lenticular lens sheet 52 has a function of expanding the image light that has passed through the Fresnel lens sheet 51 to an appropriate angle range.

  The lenticular lens sheet 52 includes a lenticular lens 57 as shown in FIG. The incident surface of the lenticular lens 57 is composed of a plurality of lens rows made of convex lenses. In the example of FIG. 3, incident light is condensed in the lens medium and then diffused in the horizontal direction. As another lenticular lens sheet, one having a lenticular lens on both sides of the sheet is disclosed (Patent Document 2).

  As a conventional method for producing a lenticular lens sheet, (1) a method of forming both front and back surfaces at once by extrusion molding, and (2) a radiation curable resin such as an ultraviolet curable resin on both sides or one side of a film substrate. (Patent Document 2 and Patent Document 3) are disclosed.

  FIG. 4 shows an apparatus for manufacturing a lenticular lens sheet disclosed in Patent Document 3. As shown in the figure, the manufacturing apparatus 70 includes a paper feed roll 72 that supplies a continuous film base 71, a molding roll 73 in which a reverse shape of the lenticular lens is formed, and a radiation curable resin applied to the molding roll 73. A coating unit 74 to be applied and a radiation lamp 75 for irradiating the radiation curable resin with radiation to the molding roll 73 are provided. In addition, the manufacturing apparatus 70 includes a resist forming apparatus 76 for forming a negative resist layer on the light output side surface of the film base 71.

  Also in the liquid crystal display device, the lens sheet plays an important function (for example, Patent Document 4). FIG. 5 is a cross-sectional view showing the configuration of the liquid crystal display device disclosed in Patent Document 4. As shown in the figure, a liquid crystal display device 80 includes a liquid crystal layer 82, an active matrix substrate 81 (support base 81a, polarizing plate 81b, TFT element 81c, insulating layer 81d, counter electrode 81e, display electrode 81f, alignment film 81g, etc. Counter substrate 83 (transparent glass support base 83a, alignment film 83b, circularly polarizing layer 83c, quarter wavelength layer 83d, alignment film) facing the active matrix substrate 81 via the liquid crystal layer 82 83e etc.), etc. A planar light source device 84 is provided on the main surface of the counter substrate 83 in the liquid crystal display device 80 on the main surface that does not face the liquid crystal layer 82. In the planar light source device 84, a prism sheet 85, a light diffusion sheet 86, a light guide plate 87, and a reflection plate 88 are provided in this order from the counter substrate 83 side. A light source 89 is attached to one side surface of the reflection plate 88.

The prism lens sheet 85 plays a role of collimating the light that has passed through the light diffusion sheet 86. The prism lens sheet 85 includes a prism lens 85a as shown in FIG.
JP 2005-10545 A JP 2000-180971 A JP-A-1-159627 JP 9-258210 A

In manufacturing the lenticular lens sheet and the prism lens sheet, it is ideal to manufacture them by a simpler method.
On the other hand, in recent years, the number of pixels of projectors is increasing in order to achieve high definition of video image quality. Along with this, a fine pitch (for example, a lens pitch of 0.2 mm or less) provided in the lenticular lens sheet is required. For this reason, the technique which makes a fine pitch simply the female type | mold at the time of using an extrusion molding method, the forming roll 73 in the manufacturing apparatus shown in FIG. 4, etc. is needed.

  In the above, the problems in the lenticular lens sheet and the prism lens sheet have been described. However, the present invention is not limited to this, and similar problems may occur in general optical components such as a lens sheet including a Fresnel lens sheet. .

  The present invention has been made in view of the above background, and the object of the present invention is to provide a method for manufacturing an optical component or the like that can be finely pitched and can be accurately and easily formed. Is to provide.

  The method for manufacturing an optical component or the like according to the present invention repeats collective exposure in units of projection areas, thereby selectively irradiating light to a photocurable resin liquid to form a cured resin layer. The three-dimensional structure is formed by sequentially laminating. The present invention is particularly effective when the structure of an optical component or the like is a complicated three-dimensional structure having an overhang portion.

Here, in the case where the area of the projection region is 100 mm ² or less, the optical component or the like can be formed with higher accuracy by using the optical modeling method according to the present invention.
Similarly, when the thickness of one layer of the cured resin layer is 10 μm or less, an optical component or the like can be formed with higher accuracy by using the optical modeling method according to the present invention.

  The method for producing an optical component or the like according to the present invention is suitably used when the photocurable resin liquid is cured by light reflected by a digital mirror device.

  In the method for manufacturing a mold for optical parts according to the present invention, a mold for optical parts made of a ceramic material having higher strength can be formed by blending ceramic powder with the photocurable resin liquid. it can.

  ADVANTAGE OF THE INVENTION According to this invention, it has the outstanding effect that fine pitch can be made and the manufacturing method of optical components etc. which can be formed accurately and simply can be provided.

  Hereinafter, an example of an embodiment to which the present invention is applied will be described. It goes without saying that other embodiments may also belong to the category of the present invention as long as they match the gist of the present invention.

[Embodiment 1 (Method for Manufacturing Optical Component)]
FIG. 1 is a diagram for explaining an example of a device configuration of a photo-curing modeling apparatus (hereinafter referred to as “optical modeling apparatus”) that manufactures a lenticular lens sheet that is an optical component according to the first embodiment. As shown in the figure, the optical modeling apparatus 100 includes a light source 1, a digital mirror device (hereinafter abbreviated as “DMD”) 2, a lens 3, a modeling table 4, a dispenser 5, a recoater 6, a control unit 7, and a storage unit 8. Etc.

  The light source 1 is mounted with a laser beam capable of oscillating. The photo-curable resin liquid can be cured by irradiating a photo-curable resin liquid described later with a laser beam generated from the light source 1. Therefore, it is necessary to mount a laser beam having a wavelength at which the coat layer 9 of the photocurable resin liquid 10 is cured. Specific examples of the light source 1 include a laser diode (LD) that generates 405 nm laser light and an ultraviolet (UV) lamp.

  The digital mirror device (DMD) 2 is a device developed by Texas Instruments, and hundreds of thousands to millions of micromirrors that move independently on a CMOS semiconductor, for example, 480,000 to 1.31 million are spread. It is what has been. Individual micromirrors can be tilted by about ± 10 degrees, for example, about ± 12 degrees about the diagonal line by an electrostatic field effect. By controlling the angle of each micromirror, it is possible to irradiate a desired position of a photocurable resin liquid formed on a modeling table described later.

  The micromirror provided in the DMD 2 has a square shape in which the length of one side of the pitch of each micromirror is about 10 μm, for example, 13.68 μm. The interval between adjacent micromirrors is, for example, 1 μm. The entire DMD 2 used in the first embodiment has a square shape of 40.8 × 31.8 mm (of which the mirror portion has a square shape of 14.0 × 10.5 mm). It is composed of 786,432 micromirrors having a length of 13.68 μm. The laser beam emitted from the light source 1 is reflected by a micromirror that is a constituent member of the DMD 2. In the DMD 2, the laser beam reflected toward the condensing lens 3 is irradiated to the photocurable resin liquid 10 on the modeling table 4.

  The lens 3 plays a role of guiding the laser beam reflected by the DMD 2 onto the photocurable resin liquid 10 to form a projection region. The lens 3 may be a condenser lens using a convex lens or a concave lens. When a concave lens is used, a projection area larger than the actual size of DMD 2 can be obtained. The lens 3 according to the first embodiment is a condensing lens composed of a convex lens, and reduces incident light about 15 times and condenses it on a coat layer 9 formed of the photocurable resin liquid 10.

  The modeling table 4 is composed of a flat mounting table. The coating layer 9 of the photocurable resin liquid 10 is formed on the modeling table 4, and the photocurable resin liquid 10 is cured by being irradiated with a laser beam through the lens 3. The modeling table 4 is configured so that horizontal movement and vertical movement can be freely moved by a driving mechanism (not shown), that is, a moving mechanism. With this drive mechanism, stereolithography can be performed over a desired range. The dispenser 5 is configured to store the photocurable resin liquid 10 and supply a predetermined amount of the photocurable resin liquid 10 to a predetermined position. The recoater 6 includes, for example, a blade mechanism and a moving mechanism, and is configured so that the photocurable resin liquid 10 can be uniformly applied.

  The control unit 7 controls the light source 1, DMD 2, modeling table 4, dispenser 5, and recoater 6 according to control data including exposure data. The control unit 7 can typically be configured by installing a predetermined program in a computer. A typical computer configuration includes a central processing unit (CPU) and memory. The CPU and the memory are connected to an external storage device such as a hard disk device as an auxiliary storage device via a bus. This external storage device functions as the storage unit 8 of the control unit 7. A storage medium drive device such as a flexible disk device, a hard disk device, or a CD-ROM drive that functions as the storage unit 8 is connected to a bus via various controllers. A portable storage medium such as a flexible disk is inserted into a storage medium driving apparatus such as a flexible disk apparatus. The storage medium can store a predetermined computer program for executing the present embodiment by giving instructions to the CPU in cooperation with the operating system.

  The storage unit 8 stores control data including exposure data of cross-sectional groups obtained by slicing a three-dimensional model to be modeled into a plurality of layers. Based on the exposure data stored in the storage unit 8, the control unit 7 mainly controls the angle control of each micromirror in the DMD 2 and the movement of the modeling table 4 (that is, the position of the laser beam irradiation range with respect to the three-dimensional model). Instructing the modeling of the three-dimensional model.

  The computer program is executed by being loaded into a memory. The computer program can be compressed or divided into a plurality of pieces and stored in a storage medium. In addition, user interface hardware can be provided. Examples of the user interface hardware include a pointing device for inputting such as a mouse, a keyboard, or a display for presenting visual data to the user.

As the photocurable resin liquid 10, one that is cured by a laser beam is selected. As the laser beam, for example, visible light or ultraviolet light can be suitably used. For example, an acrylic resin corresponding to 405 nm having a curing depth of 15 μm or more (500 mJ / cm ² ) and a viscosity of 1500 to 2500 Pa · s (25 ° C.) can be used.

  Next, the optical modeling operation of the optical modeling apparatus 100 according to the first embodiment will be described. First, the uncured photocurable resin liquid 10 is accommodated in the dispenser 5. The modeling table 4 is in the initial position. The dispenser 5 supplies the stored photocurable resin liquid 10 on the modeling table 4 by a predetermined amount. The recoater 6 sweeps the photocurable resin liquid 10 so as to stretch and forms a coat layer 9 for one layer to be cured.

The laser beam emitted from the light source 1 enters the DMD 2. DMD 2 is controlled by control unit 7 in accordance with the exposure data stored in storage unit 8, and adjusts the angle of the micromirror corresponding to the portion that irradiates photocurable resin liquid 10 with the laser beam. As a result, the laser beam reflected from the micromirror is applied to the coating layer 9 of the photocurable resin liquid 10 through the condenser lens 3, and the laser beam reflected from the other micromirrors is applied to the photocurable resin liquid 10. The coat layer 9 is not irradiated. Irradiation of the laser beam to the photocurable resin liquid 10 is performed for 0.4 seconds, for example. At this time, the projection region of the photocurable resin liquid 10 onto the coat layer 9 is, for example, about 1.3 × 1.8 mm, and can be reduced to about 0.6 × 0.9 mm. The area of the projection region is usually desirably 100 mm ² or less.

  By using a concave lens for the lens 3, the projection area can be expanded to about 6 × 9 cm. If the projection area is enlarged beyond this size, the energy density of the laser beam applied to the projection area is lowered, so that the photocurable resin liquid 10 may be insufficiently cured. When forming a three-dimensional model larger than the size of the laser beam projection area, it is necessary to irradiate the entire modeling area by moving the irradiation position of the laser beam, for example, by horizontally moving the modeling table 4 by a moving mechanism. is there. Laser beam irradiation is performed one shot at each projection area. Control of laser beam irradiation to each projection area will be described in detail later.

  In this way, by moving the projection area and performing irradiation of the laser beam with each projection area as a unit, that is, exposure, the coat layer 9 of the photocurable resin liquid 10 is cured, and the first layer A cured resin layer is formed. The lamination pitch for one layer, that is, the thickness of one cured resin layer is, for example, 1 to 50 μm, preferably 2 to 10 μm, and more preferably 5 to 10 μm. In the conventional optical modeling method, it is difficult to increase the resolution of the modeled object, and the typical resolution is several tens of μm, and it is difficult to use it for manufacturing an optical component that requires higher resolution. According to the optical modeling method according to the first embodiment, for example, the resolution can be increased to about 5 μm in the stacking direction, and the planar resolution parallel to the modeling table can be increased to about 2 μm.

  Subsequently, a second layer of a three-dimensional model having a desired shape is simultaneously formed in the same process. Specifically, the photocurable resin liquid 10 supplied from the dispenser 5 is applied to the outside of the cured resin layer formed as the first layer so as to be stretched beyond the three-dimensional model by the recoater 6. Then, a second cured resin layer is formed on the first cured resin layer by irradiating with a laser beam. Thereafter, the third and subsequent cured resin layers are sequentially deposited in the same manner. And after completion | finish of deposition of the last layer, the modeling thing formed on the modeling table 4 is taken out. The molded object removes the uncured photocurable resin liquid adhering to the surface by washing or other methods. Thereafter, the molded article may be further irradiated with an ultraviolet lamp or the like as necessary to further cure.

  Next, an example of an optical component that can be manufactured by the manufacturing method according to the present embodiment will be described. As long as the three-dimensional structure of the optical component is within the range of the resolution of the above-described stereolithography apparatus, an arbitrary structure can be manufactured. The method for manufacturing an optical component or the like according to this embodiment is particularly suitable for manufacturing an optical component or the like having a complicated three-dimensional structure having an overhang portion. As a specific example of the three-dimensional structure having an overhang portion, a structure of a lenticular lens sheet 20 having lenticular lenses on both sides as shown in FIG.

  Here, “having an overhang portion” means that the overhang portion is present at least in part when viewed from the vertical direction even when the three-dimensional structure is rotated and installed in any direction. To do. In addition, the overhang portion is a portion having a structure in which the horizontal width of the upper portion is larger than the horizontal width of a certain portion. Typically, the overhang portion is in contact with the column portion and the column portion than the column portion. However, it is not limited to a linear structure, but includes a shape having a curved surface that rises in the vertical direction and protrudes in the horizontal direction, and a so-called reverse tapered shape. It is a concept. For example, the cylindrical shape is an overhang when viewed from the vertical direction with the cylindrical side in contact with the horizontal plane, but there is no overhang when viewed from the vertical direction with the bottom in contact with the horizontal plane. It is not a three-dimensional structure having an overhang portion. On the other hand, the spherical shape is a three-dimensional structure having an overhang portion. The manufacturing method of the present invention is particularly suitable for modeling a three-dimensional structure having an overhang portion. If the structure has no overhang portion when viewed from a certain direction, the overhang portion is essentially difficult to manufacture. This is because even if other manufacturing methods are used, it may be possible to form the three-dimensional structure.

  A lenticular lens sheet 20 shown in FIG. 2A includes a first lenticular lens 21 and a second lenticular lens 22. Information related to the three-dimensional structure of the lenticular lens sheet 20 is stored in the storage unit 8. And for example, in order to model from the 2nd lenticular lens 22 side, the coating layer 9 for one layer which hardens the photocurable resin liquid 10 to the modeling table 4 via the dispenser 5 is formed. Then, based on the exposure data stored in the storage unit 8, the control unit 7 controls the angle of each micromirror in the DMD 2, performs one-shot laser beam irradiation for each projection region, and performs a desired position. The coat layer 9 is cured. Thereafter, the coat layer 9 of the photocurable resin liquid 10 is formed on the upper layer through the dispenser 5 and the above method is repeated. Thereby, the 2nd lenticular lens 22 can be formed, an internal solid structure part can be comprised, and the 1st lenticular lens 21 can be formed subsequently. Of course, you may model from the 1st lenticular lens 21 side. The pitch of the first lenticular lens 21 can be set to 0.2 mm, for example, and the second pitch can be set to 0.1 mm, for example.

  Also, a lenticular lens sheet 30 having a lenticular lens as shown in FIG. 2B on only one side can be manufactured. A base film may be used for the solid structure region 32 other than the lenticular lens 31. This makes it possible to select a material having a mechanical strength stronger than that of the photocurable resin liquid 10 and to increase the mechanical strength of the lenticular lens. In this case, the base film may be placed on the modeling table 4 in advance, and the coating layer 9 may be formed thereon and repeatedly formed by photocuring. Also, a prism lens sheet 85 as shown in FIG. 5 can be manufactured.

  The photocurable resin liquid used in Embodiment 1 is not particularly limited, but a photocurable resin liquid composition comprising a radical polymerizable compound and / or a cationic polymerizable compound is usually preferable. Used for. In addition, a photopolymerization initiator corresponding to radical polymerization or cationic polymerization is usually added to these photocurable resin liquid compositions.

  The three-dimensional object made of the cured product obtained by the above-described stereolithography method is taken out from the stereolithography apparatus, and after removing the unreacted composition (uncured) remaining on the surface and inside thereof, it is washed as necessary. To do. Here, as the cleaning agent, alcohol-based organic solvents typified by alcohols such as isopropyl alcohol and ethyl alcohol; ketone-based organic solvents typified by acetone, ethyl acetate, methyl ethyl ketone, etc .; aliphatics typified by terpenes Based organic solvents.

  According to the first embodiment, a desired lenticular lens or the like is accurately and easily shaped by repeating the light irradiation and the coating of the photocurable resin liquid while switching the cross section handled in the light irradiation process to the adjacent cross section. be able to. It is also possible to cope with fine pitches such as lenticular lenses. Further, there is an advantage that lenticular lens sheets having different lens pitches, lens thicknesses, and shapes can be easily and quickly manufactured only by rewriting exposure data stored in the storage unit 8. Therefore, it is particularly suitable for providing optical parts such as a small amount of various types of lenticular lenses and order-made optical parts. Moreover, the structure which has an overhang structure which equips both surfaces with a lenticular lens can be formed simply and rapidly.

[Embodiment 2 (Manufacturing method of mold for optical component)]
Next, the manufacturing method of the optical component mold will be described. The basic stereolithography method is the same as that of the first embodiment except for the following points. That is, in the said Embodiment 1, although optical components themselves were modeled and manufactured by the optical modeling method, in this Embodiment 2, the type | mold used for manufacture of an optical component is modeled and manufactured by the optical modeling method. Is different. Here, the mold includes a female mold and a master mold. Both can be modeled and manufactured by the optical modeling method. Here, the female mold refers to a mold that copies the shape from the mold and manufactures an optical component. This is a mold for producing the female mold described above.

  The lenticular lens sheet 20 having lenticular lenses on both sides as shown in FIG. 2A is formed, for example, by bonding a first female substrate and a second female substrate, and its internal space. Can have a shape of the lenticular lens sheet 20 as a mold. In this case, the first female substrate and the second female substrate are filled with the resin solution for the lens sheet, and then the substrates are joined while being aligned, and an external stimulus is applied by heat or light. A lenticular lens sheet can be obtained by curing the lens sheet resin solution. In addition, an injection port for the resin liquid for the lens sheet that communicates with the internal space may be provided on either the first female substrate or the second female substrate. Here, the lens sheet resin liquid is particularly limited as long as it is a resin that satisfies the requirements such as transparency required for the lenticular lens sheet 20 and can be cured by an appropriate method after being poured into a mold and filled. Not. For example, after filling a thermosetting uncured resin liquid such as acrylic resin, heat may be applied to cure inside the mold, or the thermoplastic resin is melted and filled, and then cooled inside the mold. May be.

  The lenticular lens sheet 30 having a lenticular lens on one side as shown in FIG. 2B is formed by joining a flat plate and a female substrate, and its internal space has the shape of the lenticular lens sheet 30. Can be used. The forming roll itself as shown in FIG. 4 can be manufactured as a female mold by an optical modeling method.

  When manufacturing an optical component from a female mold, for example, a silane compound having a hydrolyzable group is injected into the female mold, and a hydrolysis / condensation reaction is caused by heating or the like. A three-dimensional structure made of polysiloxane is obtained. An optical component can be obtained by separating the three-dimensional structure from the female mold. If the structure of the female mold is complicated, the female mold may not be peeled unless the female mold is destroyed. In such a case, for example, the cured resin constituting the female mold is burned away by heat treatment at 300 ° C. for about 6 hours, or the ultrasonic treatment is performed for about 1 hour by immersing in an organic solvent such as ethanol. The female mold can be destroyed by a method such as swelling of the cured resin constituting the mold. Even if the female mold made of the photocurable resin liquid does not break due to peeling, the mechanical strength is inferior to that of a mold or the like, so the number of times that an optical component can be manufactured is limited. However, unlike a mold, a female mold can be obtained easily and quickly, which is effective when trial manufacture of optical components having various shapes.

  When it is desired to produce a mold for a lenticular lens sheet with ceramic, ceramic powder can be blended with the photocurable resin liquid composition. The number average particle diameter is usually 0.01 to 0.5 μm as measured by electron microscopy. Preferably, it is 0.02-0.3 micrometer, More preferably, it is 0.05-0.2 micrometer. The particle size of the ceramic powder is measured by electron microscopy, but scanning electron microscopy is particularly preferred. The shape of the ceramic powder is not particularly limited as long as it has a granularity that can define the particle size. For example, it is not limited to a spherical shape, and may be a pulverized body or the like. The particle diameter in the case of a shape other than a spherical shape is defined by the maximum diameter in the electron microscope image.

  The material constituting the ceramic powder is not particularly limited as long as it does not substantially absorb the light having the irradiation wavelength. For example, oxides such as alumina, zirconia, titania, zinc oxide, ferrite, barium titanate, apatite, silica, carbides such as zirconium carbide and silicon carbide, nitrides such as aluminum nitride, silicon nitride, and sialon (SiAlON), or Various ceramics such as a mixture thereof can be used. Usually, as the component (A), alumina, zirconia, silica, aluminum nitride, silicon nitride, or a mixture thereof is preferably used.

  When a three-dimensional product obtained by photocuring a photocurable resin liquid containing a ceramic powder is fired, a mold for a lenticular lens sheet made of a ceramic fired body can be obtained. The firing method used here is not particularly limited, and a known method can be used.

  In the case of manufacturing an optical component from a master mold, for example, after Ni electroforming is performed on the surface of the master mold, the master mold is peeled off to produce a female mold in which the shape of the master mold is copied. Thereby, a female die can be obtained. Then, using this female mold, a silane compound having a hydrolyzable group is injected and reacted in the same manner as described above, and the optical component made of polysiloxane can be obtained by peeling from the female mold.

  In the lenticular lens sheet 20 having lenticular lenses on both sides as shown in FIG. 2A, a master mold of the lenticular lens sheet 20 is manufactured, and Ni electroforming is performed as necessary. Using this as a master mold, a female mold with a housing structure having the shape of a lenticular lens sheet in the internal space is obtained. A lens sheet resin liquid inlet may be provided on the surface of the housing structure to communicate with the internal space. In the lenticular lens sheet 30 having a lenticular lens on one side as shown in FIG. 2B, a master mold can be manufactured in the same manner.

  As the master die of the forming roll as shown in FIG. 4, it is formed by joining the first master die and the second master die, and the inner space has the shape of the forming roll 73. Can be used. When manufacturing a female mold, the first master mold and the second master mold are filled with a resin solution for lens sheet, and then these substrates are joined while being aligned, and heat or light is applied. The molding roll 73 can be obtained by applying an external stimulus to cure the lens sheet resin liquid. Moreover, you may provide the injection port of the resin liquid for lens sheets connected to internal space in either a 1st master type | mold or a 2nd master type | mold.

  In the first embodiment and the second embodiment, the example of the lenticular lens has been described. However, the present invention is not limited to this example, and the present invention is applied to general optical components such as a lens sheet including a Fresnel lens sheet and a prism lens sheet. The invention can be applied.

FIG. 3 is an explanatory diagram illustrating an example of a schematic configuration of the optical modeling apparatus according to the first embodiment. (A) is sectional drawing of the lenticular lens sheet | seat which equips both surfaces which concern on Embodiment 1 and 2 with a lenticular lens, (b) is a cross section of a lenticular lens sheet | seat which has a lenticular lens on the single side | surface which concerns on Embodiment 1 and 2. Figure. The perspective view which shows an example of a structure of the transmission type screen which concerns on a prior art example. The perspective view which shows the structure of the manufacturing apparatus of the lenticular lens sheet which concerns on a prior art example. Sectional drawing which shows an example of a structure of the liquid crystal display device which concerns on a prior art example.

Explanation of symbols

1 Light source 2 DMD
DESCRIPTION OF SYMBOLS 3 Condensing lens 4 Modeling table 5 Dispenser 6 Recoater 7 Control part 8 Memory | storage part 9 Photocurable resin liquid 10 Photocurable resin liquid 20 Lenticular lens sheet 21 1st lenticular lens 22 2nd lenticular lens 30 Lenticular lens sheet 31 Lenticular lens 32 Solid structure region 100 Stereolithography apparatus

Claims (14)

  By repeating collective exposure with the projection area as a unit, selectively irradiating light to the photocurable resin liquid to form a cured resin layer, and sequentially laminating the cured resin layer to form a three-dimensional structure. A method for manufacturing an optical component.   The method for manufacturing an optical component according to claim 1, wherein the three-dimensional structure of the optical component has an overhang portion. The method of manufacturing an optical component according to claim 1, wherein an area of the projection region is 100 mm ² or less.   The method for manufacturing an optical component according to any one of claims 1 to 3, wherein a thickness of one layer of the cured resin layer is 10 µm or less.   The method of manufacturing an optical component according to claim 1, wherein the photocurable resin liquid is cured by light reflected by a digital mirror device.   By repeating collective exposure with the projection area as a unit, selectively irradiating light to the photocurable resin liquid to form a cured resin layer, and sequentially laminating the cured resin layer to form a three-dimensional structure. A method for producing a mold for optical parts, which is characterized.   The manufacturing method of the type | mold for optical components of Claim 6 with which the three-dimensional structure of the said optical component has an overhang part. The method for manufacturing a mold for optical components according to claim 6 or 7, wherein the area of the projection region is 100 mm ² or less.   9. The method for manufacturing a mold for optical components according to claim 6, wherein the thickness of one layer of the cured resin layer is 10 μm or less.   The method for producing a mold for an optical component according to any one of claims 6 to 9, wherein the photocurable resin liquid is cured by light reflected by a digital mirror device.   The method for manufacturing an optical component mold according to any one of claims 6 to 10, wherein the optical component mold is a female mold for manufacturing an optical component.   The method for manufacturing an optical component mold according to any one of claims 6 to 10, wherein the optical component mold is a master mold for manufacturing a female mold for an optical component.   The method for manufacturing a mold for optical components according to claim 11 or 12, wherein the photocurable resin liquid contains ceramic powder.   The optical component manufactured using the mold for optical components manufactured by the manufacturing method of the mold for optical components of any one of Claims 6-13.

Images