JP2010066518A - Fresnel lens, device for manufacturing fresnel lens and method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a Fresnel lens, a device for manufacturing a Fresnel lens and a method thereof. <P>SOLUTION: In the Fresnel lens, the device for manufacturing a Fresnel lens and the method thereof, the Fresnel lens includes a substrate formed of a glass material and a Fresnel structure formed of a plastic material integrated onto the substrate. The manufacturing method includes a step to add a plastic material to a forming apparatus, a step to solidify the plastic material to form a Fresnel structure, and a step to separate the forming apparatus to form the Fresnel structure on the substrate in an integrated manner, thereby forming a Fresnel lens. The device for manufacturing a Fresnel lens is equipped with the forming apparatus connected to the substrate of the Fresnel lens, and the forming apparatus has a forming part corresponding to the Fresnel structure of the Fresnel lens. The forming part forms the plastic material into the Fresnel structure. Thereby, the Fresnel structure of a plastic material is formed on the substrate of a glass material in an integrated manner such that the Fresnel lens has the characteristics of low costs of the plastic lens and high weatherability of the glass lens. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to lenses, and more particularly to Fresnel lenses and apparatus and methods for manufacturing Fresnel lenses.

As shown in FIG. 13, the Fresnel lens 8 has the optical function of a general lens 7, but has an advantage of a smaller volume and weight than the general lens 7, and gradually becomes a general lens 7. Has been replaced. The Fresnel lens 8 mainly needs to have a large area lens, but on a product that desires to reduce the weight and material of the lens, for example, a navigation light source projected by a lighthouse, a lens of a projection film projector, a rear projection display It is applied to screens, lightweight type magnifiers, etc. Most of the current Fresnel lens 8 is formed of a single glass material or plastic material.

The Fresnel lens 8 made of glass and the Fresnel lens 8 made of plastic can be operated differently. For example, the light intensity through the Fresnel lens 8 is relatively high or it is placed outdoors and requires high weather resistance. Usually, a stable glass material Fresnel lens 8 is used. Glass-made Fresnel lenses 8 are mostly manufactured using conventional polishing assembly, direct processing molding, or casting techniques, and the high hardness and high molding temperature of glass increase the manufacturing cost and limit the manufacturing area. Accordingly, most of the small glass-made Fresnel lens 8 is manufactured by a casting technique, and the large glass-made Fresnel lens 8 is generally manufactured by a method in which a large number of lenses are combined.

  When the light intensity of the Fresnel lens 8 is low or placed in a room and requires a light volume or low cost, a Fresnel lens 8 made of plastic is usually used. Most of the plastic Fresnel lens 8 is manufactured by a method such as injection, direct processing, pressure casting, roller press, die casting, etc., and has a low manufacturing cost.

With the rapid development of solar energy applications, solar energy concentrating modules have an important position during solar energy applications. For example, in the solar energy power generation system, the large Fresnel lens 8 having weather resistance is one of the light collecting units required by the solar energy collecting module.
Registered Utility Model No. 3074896

However, the glass-made Fresnel lens 8 is not only expensive, but the large single-piece Fresnel lens 8 requires high manufacturing difficulty.

  Also, in the application of projecting strong light, when selecting the Fresnel lens 8, it has the same requirements as the solar energy condensing module, under the requirements of projection illumination of intense light source or light guide illumination of high intensity light source. Only when the glass-made Fresnel lens 8 is employed can meet the high-intensity requirements of strong light projection. As described above, when the glass-made Fresnel lens 8 is employed, not only the cost is high, but also the difficulty of production technology is high.

A first object of the present invention is to provide a Fresnel lens that is low in cost and high in weather resistance.

Based on the above first object, the Fresnel lens of the present invention is provided with a substrate and a Fresnel structure, the substrate is formed of a glass material, and the Fresnel lens structure is integrally formed on the substrate from a plastic material. Therefore, the Fresnel lens has advantages such as low cost of the plastic lens and high weather resistance of the glass lens.

A second object of the present invention is to provide a method for manufacturing a Fresnel lens, in which a glass Fresnel structure is integrally formed on a glass substrate.

Based on the second object, the Fresnel lens manufacturing method of the present invention includes the following steps:
Step 1: Inject plastic material into the molding apparatus;
Step 2: solidify the plastic material to form a Fresnel structure;
Step 3: The molding apparatus is separated, the Fresnel structure is integrally molded on the substrate, and the Fresnel lens is molded.

  A third object of the present invention is to provide an apparatus for manufacturing a Fresnel lens capable of integrally molding a plastic Fresnel structure on a glass substrate.

  Based on the third object, the Fresnel lens manufacturing apparatus of the present invention is provided with a molding device connected to the substrate of the Fresnel lens, the molding device is provided with a molding part corresponding to the Fresnel structure of the Fresnel lens, and the molding part is plastic. Used to mold material into Fresnel structure.

  As can be seen from the above description of the object, the Fresnel lens of the present invention is formed by integrally forming a plastic Fresnel structure on a glass substrate by a molding apparatus, and the Fresnel lens has a low cost plastic lens and a high weather resistance of the glass lens. Gives benefits such as sex.

In order to describe the technical contents of the present invention, the objects to be achieved, and the effects in detail, examples will be given below and described in detail in conjunction with the drawings.

As shown in FIG. 1, the Fresnel lens 1 of the present invention includes a substrate 10 and a Fresnel structure 11, the substrate 10 is made of a glass material, the Fresnel structure 11 is made of a plastic material, and is integrated with the surface of the base 10. In practice, the thickness of the Fresnel structure 11 can be less than 2.5 mm.

The main component of the Fresnel lens 1 of the present invention is mainly a glass substrate 10, and only the Fresnel structure 11 is formed of a plastic material, so that a small and medium-sized Fresnel lens 1 can be directly manufactured, and the region and time Therefore, the Fresnel lens 1 having a large area can be manufactured by dividing the lens. Therefore, the Fresnel lens 1 has advantages such as low cost of the plastic lens and high weather resistance of the glass lens.

The substrate 10 of the Fresnel lens 1 of the present invention can be a flat plate, a trapezoidal flat plate, a convex plate, a concave plate, or a combination thereof. The Fresnel structure 11 can be molded into the apparatus by adding a heat-settable plastic material or a light-settable plastic material. After the set, the Fresnel structure 11 is molded integrally on the substrate 10. The heat-settable plastic material can be silicon and the light-settable material can be an epoxy resin or an acrylic resin.

As shown in FIGS. 2 and 3, FIG. 2 is a step explanatory view of the first embodiment of the method for manufacturing the Fresnel lens 1 of the present invention, and FIG. 3 shows the first method of manufacturing the Fresnel lens 1 of the present invention. It is a step flow figure of one Example. In this embodiment, the molding apparatus is the mold 2, the molding part is the Fresnel-shaped cavity 20 of the mold 2, and the method for manufacturing the Fresnel lens 1 includes the following steps:
Step 1: Fix the mold 2;
Step 2: Add plastic material 3 into Fresnel cavity 20 of mold 2 and fill plastic material 3 with Fresnel cavity 20;
Step 3: Cover substrate 10 onto Fresnel cavity 20 and bond substrate 10 to plastic material 3 together;
Step 4: solidify the plastic material 3 to form the Fresnel structure 11;
Step 5: The mold 2 is separated, and the Fresnel structure 11 is integrally formed on the substrate 10 to form the Fresnel lens 1.

In this embodiment, the solidification method can be solidification by heating or solidification by ultraviolet irradiation according to the characteristics of the plastic material 3. Further, this manufacturing process can be performed in a vacuum chamber, and when the substrate 10 covers the Fresnel-shaped cavity 20, it is possible to avoid the generation of bubbles between the substrate 10 and the plastic material 3. .

As shown in FIGS. 4 and 5, FIG. 4 is a step explanatory view of the second embodiment of the method for manufacturing the Fresnel lens 1 of the present invention, and FIG. 5 shows the step of the method for manufacturing the Fresnel lens 1 of the present invention. It is a step flow figure of 2 examples. In this embodiment, the molding apparatus is the mold 2 and the annular sleeve 4, the molding part is the Fresnel-shaped cavity 20 of the mold 2, and the manufacturing method of the Fresnel lens 1 includes the following steps:
Step 1: Fix the mold 2;
Step 2: Place the annular sleeve 4 on the substrate 10;
Step 3: Add the plastic material 3 into the open space formed by the substrate 10 and the annular sleeve 4;
Step 4: The mold 2 is joined to the annular sleeve 4 and at the same time the plastic material 3 is filled into the sealed space formed by the substrate 10 and the Fresnel cavity 20 of the mold 2;
Step 5: solidify the plastic material 3 to form the Fresnel structure 11;
Step 6: The mold 2 and the annular sleeve 4 are separated, and the Fresnel structure 11 is integrally formed on the substrate 10 to form the Fresnel lens 1.

In this embodiment, an annular sleeve 4 having a different size can be selected and combined with the mold 2 to produce a Fresnel lens 1 having a different size.

In the manufacturing methods of the first embodiment and the second embodiment, the solidification step can be achieved by heat solidification or ultraviolet irradiation solidification based on the characteristics of the plastic material 3. The manufacturing flow can be performed in a vacuum chamber, and avoids the generation of bubbles between the Fresnel cavity 20 and the plastic material 3 when the mold 2 and the annular sleeve 4 and the substrate 10 are joined to each other.

As shown in FIGS. 6 to 8, FIG. 6 is a step explanatory view of the third embodiment of the method for manufacturing the Fresnel lens 1 of the present invention, and FIG. 7 is the step of the method for manufacturing the Fresnel lens 1 of the present invention. FIG. 8 is a step flow diagram of the third embodiment, and FIG. 8 is an explanatory diagram of the mold passage of the present embodiment. In this embodiment, the molding apparatus is the mold 2, the molding part is the Fresnel cavity 20 of the mold 2, and the manufacturing method of the Fresnel lens 1 includes the following steps:
Step 1: The substrate 10 and the mold 2 are joined to form a sealed space in the Fresnel cavity 20 of the substrate 10 and the mold 2 so that the mold 2 has a passage 21 that passes through the Fresnel cavity 20;
Step 2: Add the plastic material 3 through the passage 21 and fill the sealed space formed by the substrate 10 and the Fresnel cavity 20 with the plastic material 3;
Step 3: solidify the plastic material 3 to form the Fresnel structure 11;
Step 4: The mold 2 is separated, and the Fresnel structure 11 is integrally formed on the substrate 10 to form the Fresnel lens 1.

In the manufacturing method of this embodiment, when a plastic material is added, the plastic material can be filled into a sealed space formed by the substrate and the Fresnel cavity by high pressure injection or vacuum suction.

As shown in FIGS. 9 to 12, FIG. 9 is a step explanatory view of the fourth embodiment of the method for manufacturing the Fresnel lens 1 of the present invention, and FIG. 10 shows the step of the method for manufacturing the Fresnel lens 1 of the present invention. FIG. 11 is a step flow diagram of the fourth embodiment, FIG. 11 is an explanatory diagram of the first molded plate in the present embodiment, and FIG. 12 is an explanatory diagram of the second molded plate in the present embodiment. In this embodiment, the molding device is the first molding plate 5 and the annular sleeve 4, the molding part is the Fresnel-shaped groove 50 on the side of the first molding plate 5, and the method for manufacturing the Fresnel lens 1 includes the following steps. Including:
Step 1: fixing the substrate 10;
Step 2: Place the annular sleeve 4 on the substrate 10;
Step 3: Add the plastic material 3 to the open space formed by the substrate 10 and the annular sleeve 4;
Step 4: the plastic material 3 is solidified, and the plastic material 3 is formed to be semi-solid;
Step 5: Push the Fresnel-shaped groove 50 on the side of the first forming plate 5 into the semi-solidified plastic material 3;
Step 6: The first molded plate 5 is rotated to continuously solidify the semi-solidified plastic material 3 to form the Fresnel structure 11;
Step 7: The first molding plate 5 and the annular sleeve 4 are separated, and the Fresnel structure 11 is integrally molded on the substrate 10 to form the Fresnel lens 1.

In this embodiment, the length of the first molded plate 5 is the length of the diameter of the Fresnel structure 11 of the Fresnel lens 1, and the Fresnel-shaped concave groove 50 of the first molded plate 5 is the entire Fresnel structure 11 of the Fresnel lens 1. Corresponding to the shape of the transverse cut surface, the upper side of the Fresnel-shaped groove 50 is provided with a hypotenuse 51. When the first molding plate 5 rotates, the hypotenuse 51 at the top of the Fresnel-shaped groove 50 presses the plastic material 3 to cause the plastic material 3 to mold the Fresnel structure 11.

In this embodiment, the second molded plate 6 is used in place of the first molded plate 5, the Fresnel structure 11 is molded into the plastic material 3, the semi-Fresnel-shaped groove 60 is provided on the side of the second molded plate 6, and the second The length of the molding plate 6 is the length of the radius of the Fresnel structure 11 of the Fresnel lens 1, and the half Fresnel-shaped concave groove 60 of the second molding plate 6 is a transverse cut surface of half of the Fresnel structure 11 of the Fresnel lens 1. The upper part of the semi-Fresnel groove 60 has an arc-shaped side 61. When the second molding plate 6 rotates, the arc-shaped side 61 at the upper part of the semi-Fresnel groove 61 pushes the plastic material 3 and causes the plastic material 3 to mold the Fresnel structure 11.

The Fresnel lens 1 of the present invention can be operated in a solar energy condensing module, and concentrates sunlight incident by a large area Fresnel lens on a small area high conversion efficiency solar cell, and the solar cell energy has a large area. It is possible to receive solar energy having an area several times larger than that, and combine solar cells with high photoelectric conversion efficiency to generate electric power more efficiently.

  The Fresnel lens 1 of the present invention can also be used in an endothermic tube system. The Fresnel lens collects the amount of solar energy in the endothermic tube, and the solar endowment has an area several times the size of its own area. The fluid whose temperature is increased by increasing the temperature of the heat absorption pipe can be used in thermal energy power generation, heating equipment, hot water equipment, etc., and its performance can be greatly increased.

  In the Fresnel lens 1 of the present invention, the Fresnel structure 11 is integrally formed from the substrate 10 by the molding apparatus, for example, the mold 2, the annular sleeve 4 and the first molding plate 5, to directly manufacture the Fresnel lens 1 having a small and medium area. The Fresnel lens 1 having a large area can be manufactured by dividing the area and time, and the Fresnel lens 1 can be provided with advantages such as low cost of the plastic lens and high weather resistance of the glass lens.

It is sectional drawing of the Fresnel lens of this invention. It is step explanatory drawing of 1st Example of the manufacturing method of the Fresnel lens of this invention. It is a step flow figure of the 1st example of the manufacturing method of the Fresnel lens of the present invention. It is step explanatory drawing of 2nd Example of the manufacturing method of the Fresnel lens of this invention. It is a step flow figure of 2nd Example of the manufacturing method of the Fresnel lens of this invention. It is step explanatory drawing of 3rd Example of the manufacturing method of the Fresnel lens of this invention. It is a step flow figure of the 3rd example of the manufacturing method of the Fresnel lens of the present invention. It is explanatory drawing of the casting_mold | template channel | path of this invention. It is step explanatory drawing of 4th Example of the manufacturing method of the Fresnel lens of this invention. It is a step flow figure of the 4th example of the manufacturing method of the Fresnel lens of the present invention. It is explanatory drawing of the 1st shaping | molding board of this invention. It is explanatory drawing of the 2nd shaping | molding board of this invention. It is sectional drawing of the conventional Fresnel lens of this invention, and a general lens.

Explanation of symbols

1 Fresnel Lens 10 Substrate 11 Fresnel Structure 2 Mold 20 Fresnel Cavity 21 Passage 3 Plastic Material 4 Annular Sleeve 5 First Molded Plate 50 Fresnel Shaped Groove 51 Slanted Side 6 Second Molded Plate 60 Half Fresnel Shaped Groove 61 Arc Shape Side

Claims (19)

A substrate formed from a glass material;
A Fresnel structure formed integrally on the substrate by a plastic material;
Including Fresnel lens. The Fresnel lens according to claim 1, wherein the thickness of the Fresnel structure is 2.5 mm. The Fresnel lens according to claim 1, wherein the plastic material is a heat-settable plastic material or a light-settable plastic material. First, add plastic material into the molding equipment;
Next, the plastic material is solidified to form a Fresnel structure;
Finally, a Fresnel lens manufacturing method including separating a molding apparatus, integrally molding the Fresnel structure on a substrate, and molding a Fresnel lens. The molding apparatus is a mold, the mold provides a Fresnel cavity, and the step of adding the plastic material comprises:
Adding the plastic material into the Fresnel cavity and filling the Fresnel cavity with the plastic material;
The method for producing a Fresnel lens according to claim 4, comprising covering the substrate on a Fresnel-shaped cavity and bonding the substrate and the plastic material to each other. The method for producing a Fresnel lens according to claim 5, wherein the step of bonding the substrate and the plastic material proceeds in a vacuum chamber. The molding apparatus includes a mold and an annular sleeve, the mold is provided with a Fresnel shaped cavity, and the step of adding the plastic material comprises:
Placing the annular sleeve on the substrate;
Adding plastic material into the open space formed by the substrate and the annular sleeve;
The method for manufacturing a Fresnel lens according to claim 4, comprising joining the mold and the ring-shaped sleeve and filling the sealed space formed by the substrate and the Fresnel-shaped cavity with the plastic material. The Fresnel lens manufacturing method according to claim 7, wherein the step of joining the mold and the annular sleeve is performed in a vacuum chamber. The molding apparatus includes a mold, the mold providing a Fresnel shaped cavity, and adding the plastic material comprises:
Bonding the substrate and the mold to form a sealed space formed by the substrate and the Fresnel cavity;
The method for producing a Fresnel lens according to claim 4, further comprising adding a plastic material into the sealed space and filling the sealed space with the plastic material. The method of manufacturing a Fresnel lens according to claim 9, wherein the step of the plastic material injects the plastic material at a high pressure or vacuums the plastic material. The molding apparatus includes an annular sleeve and a molding plate, the step of providing a Fresnel-shaped concave groove on the side of the molding plate, adding the plastic material, and solidifying further,
Installing an annular sleeve on the substrate;
Adding plastic material into the open space formed by the substrate and the annular sleeve;
Solidify the plastic material to form a semi-solidified state;
Pressing a Fresnel-shaped groove into the semi-solidified plastic material;
The method for producing a Fresnel lens according to claim 4, comprising rotating the molding plate and continuing to solidify the semi-solidified plastic material to form a Fresnel structure. Interconnected with the substrate provided by the Fresnel lens, the Fresnel lens manufacturing apparatus,
A Fresnel lens manufacturing apparatus including a molding device that is connected to a Fresnel lens substrate, has a molding part, and the molding part integrally molds a plastic material on the substrate to form a Fresnel structure. The molding apparatus is
An annular sleeve used to connect the substrates and limit the molding range of the plastic material;
A mold that is joined to the annular sleeve, provided with a Fresnel cavity opposite the substrate, and wherein the plastic material is used to mold the Fresnel structure;
The fresnel lens manufacturing apparatus of Claim 12 containing.   The molding apparatus is a mold, provided with a Fresnel cavity and a passage penetrating the Fresnel cavity, the passage introduces a plastic material into the Fresnel cavity, and the Fresnel cavity molds the plastic material into a Fresnel structure. 12. A fresnel lens manufacturing apparatus according to item 12. The molding apparatus is
An annular sleeve connected to the substrate and used to limit the molding range of the plastic material;
A Fresnel-shaped groove is provided on the side of the molded plate, the Fresnel-shaped groove rotates on the plastic material, and the molded plate molds the plastic material as a Fresnel structure;
The fresnel lens manufacturing apparatus of Claim 12 containing.   The Fresnel lens manufacturing apparatus according to claim 15, wherein the Fresnel-shaped concave groove corresponds to a length of a diameter of the Fresnel structure.   The Fresnel lens manufacturing apparatus according to claim 15, wherein the Fresnel-shaped groove corresponds to a length of a radius of the Fresnel structure.   The Fresnel lens manufacturing apparatus according to claim 15, wherein an upper side of the Fresnel-shaped concave groove is provided with a hypotenuse for pushing the plastic material.   The Fresnel lens manufacturing apparatus according to claim 15, wherein an upper part of the Fresnel-shaped concave groove is provided with an arc-shaped side side into which the plastic material is pushed.

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