JP2770058B2 - Manufacturing method of lens sheet - Google Patents
Manufacturing method of lens sheetInfo
- Publication number
- JP2770058B2 JP2770058B2 JP29539389A JP29539389A JP2770058B2 JP 2770058 B2 JP2770058 B2 JP 2770058B2 JP 29539389 A JP29539389 A JP 29539389A JP 29539389 A JP29539389 A JP 29539389A JP 2770058 B2 JP2770058 B2 JP 2770058B2
- Authority
- JP
- Japan
- Prior art keywords
- mold
- ultraviolet
- resin
- lens
- lens sheet
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Moulds For Moulding Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Description
【発明の詳細な説明】 （産業上の利用分野） 本発明は、太陽光の集光、各種光源装置あるいは透過
型スクリーン等に用いられるフレネルレンズ、あるいは
透過型スクリーン等に用いられるレンチキユラーレンズ
等のレンズシートの製造方法に関するものである。DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a Fresnel lens used for condensing sunlight, various light source devices or a transmission screen, or a lenticular lens used for a transmission screen. And the like.
（従来の技術） 上記分野に使用されるフレネルレンズ等のレンズシー
トは、アクリル樹脂、ポリカーボネート樹脂、塩化ビニ
ル樹脂、あるいはスチレン樹脂等の透明樹脂材料を用
い、これをレンズ型を備えた金型を用いて射出成型する
方法や、これよりサイズが大きい場合には板材料をレン
ズ型と共に加熱、加圧して熱転写する方法、さらには板
材料に直接切削工具によつて切削する方法が知られてい
る。(Prior Art) A lens sheet such as a Fresnel lens used in the above field is made of a transparent resin material such as an acrylic resin, a polycarbonate resin, a vinyl chloride resin, or a styrene resin, and is molded into a mold having a lens mold. There is known a method of injection-molding the sheet material, a method of heating and pressing a sheet material together with a lens mold to thermally transfer the sheet material when the size is larger than this, and a method of directly cutting the sheet material with a cutting tool. .
ところが上記の方法は、概して製造装置が大規模なも
のとなり、加熱や加圧操作を伴うことから製造サイクル
が長くなり、製造コストが嵩むという問題点があつた。However, the above-described method has a problem that the manufacturing apparatus is generally large-scale and involves a heating and pressurizing operation, so that the manufacturing cycle is lengthened and the manufacturing cost is increased.
このため最近では、既存の樹脂材料を用い、この表面
に紫外線硬化型樹脂によつてレンズ部だけを形成する方
法が提案されている（特開昭54−156651号公報、特開昭
61−177215号公報、特開昭62−238502号公報参照）。For this reason, recently, a method has been proposed in which only a lens portion is formed on an existing resin material using an ultraviolet-curable resin on the surface thereof (Japanese Patent Application Laid-Open Nos.
61-177215, JP-A-62-238502).
（発明が解決しようとする課題） しかしながら、上記紫外線硬化型樹脂を用いてフレネ
ルレンズ等を製造する場合に問題となるのは、レンズ型
と透明基材との間に紫外線硬化型樹脂液を注入する際に
発生する気泡を除去することが難しいことである。この
ため上記先行例のうち特開昭61−182608号公報では、紫
外線硬化型樹脂液を減圧下で注入することが提案されて
いるが、大きなサイズのフレネルレンズを製造する場合
には設備が大規模となつてしまい製造コストの低減に寄
与しにくくなる。しかも減圧下で脱泡する場合、硬化さ
せる樹脂層の厚さが相当厚い場合には、効果が認められ
るものの、樹脂層がレンズ部のみの如く薄くなると、そ
の効果はほとんど認められなくなつてしまう難点があ
り、本来レンズ部のみを紫外線硬化型樹脂で形成して生
産性、材料コストを低減させるという目的に適合しない
こととなる。(Problems to be Solved by the Invention) However, a problem when manufacturing a Fresnel lens or the like using the above-mentioned ultraviolet-curable resin is that an ultraviolet-curable resin liquid is injected between the lens mold and the transparent substrate. It is difficult to remove the air bubbles generated at the time of cleaning. For this reason, among the above prior arts, Japanese Patent Application Laid-Open No. Sho 61-182608 proposes injecting an ultraviolet curable resin solution under reduced pressure, but when manufacturing a large-sized Fresnel lens, the equipment is large. The size is reduced, and it is difficult to reduce the manufacturing cost. In addition, when defoaming under reduced pressure, the effect is recognized when the thickness of the resin layer to be cured is considerably thick, but the effect is hardly recognized when the resin layer is thin as only the lens portion. There is a drawback, and this is not suitable for the purpose of reducing productivity and material cost by forming only the lens portion with an ultraviolet curable resin.
本発明はこのような状況に鑑み、金型に樹脂液を展延
する際に、金型中に気泡を巻き込まさせず、しかも生産
効率を低下させることのない方法を提案しようとするも
のである。The present invention has been made in view of such a situation, and aims to propose a method that does not cause bubbles to be caught in the mold when the resin liquid is spread in the mold, and that does not reduce the production efficiency. .
（課題を解決するための手段） すなわち本発明は、紫外線硬化型樹脂液をレンズシー
ト型上に展延し、この上面に透明基材を載置し、この状
態で紫外線を照射してレンズシートを製造する方法にお
いて、該レンズシート型を水平面に対し５〜30゜傾斜さ
せて紫外線硬化型樹脂液を流下、展延させ、しかるのち
紫外線を照射させることを特徴とするレンズシートの製
造方法を要旨とするものである。(Means for Solving the Problems) That is, according to the present invention, an ultraviolet-curable resin liquid is spread on a lens sheet mold, a transparent base material is placed on the upper surface, and ultraviolet rays are irradiated in this state to form a lens sheet. In the method for producing a lens sheet, the lens sheet mold is inclined at 5 to 30 ° with respect to a horizontal plane, and the ultraviolet curable resin liquid is allowed to flow down, spread, and then irradiated with ultraviolet rays. It is an abstract.
以下、本発明を図面に従つて説明する。 Hereinafter, the present invention will be described with reference to the drawings.
第１図ないし第５図は、本発明の工程の概略を示すも
ので、まずフレネルレンズやレンチキユラーレンズ等を
形成するための型面を備えたレンズシート型（１）を用
意する。このレンズシート型（１）としてはアルミニウ
ム、黄銅、鋼等の金属板やシリコン樹脂、ウレタン樹
脂、エポキシ樹脂、フツソ樹脂あるいはポリメチルペン
テン樹脂等の合成樹脂から作つたものを用いる。FIGS. 1 to 5 schematically show the steps of the present invention. First, a lens sheet mold (1) having a mold surface for forming a Fresnel lens, a lenticular lens, or the like is prepared. As the lens sheet type (1), a metal sheet made of aluminum, brass, steel or the like, or a sheet made of a synthetic resin such as a silicon resin, a urethane resin, an epoxy resin, a fluoro resin, or a polymethylpentene resin is used.
次に、上記フレネルレンズ型（１）と略同サイズの透
明基材（２）を用意する。この透明基材（２）の材質は
紫外線を通過する硝子板でもよいが、一般的にはアクリ
ル樹脂、ポリカーボネート樹脂、塩化ビニル樹脂等の透
明合成樹脂板あるいはこれらの素材またはポリエステル
等のフイルムが用いられる。Next, a transparent substrate (2) having substantially the same size as the Fresnel lens mold (1) is prepared. The material of the transparent substrate (2) may be a glass plate that transmits ultraviolet rays, but generally, a transparent synthetic resin plate such as an acrylic resin, a polycarbonate resin, or a vinyl chloride resin, or a material such as these or a film such as a polyester is used. Can be
本発明ではまず第１図のようにレンズシート型（１）
を水平面に対し５〜30゜傾けて設置する。In the present invention, first, as shown in FIG.
Is installed at an angle of 5 to 30 ° with respect to the horizontal plane.
次に、第２図のようにフレネルレンズ型（１）の傾斜
の上部に設置した流下装置（４）から、塗布予定樹脂量
の数倍以上の紫外線硬化型樹脂液（３）を流下させる。
このときに用いる紫外線硬化型樹脂としては、ポリエス
テルアクリレート系、エポキシアクリレート系、ポリウ
レタンアクリレート系等が用いられるが、流下時の粘度
が10〜80cpsの範囲にあることが好ましく、また硬化後
の透明性が高いものが望ましい。なお、樹脂液の温度が
低く粘度が高い場合には樹脂液を予熱して粘度調整をし
ておくことが望ましい。このときの紫外線硬化型樹脂液
（３）は、予め十分に脱泡しておくとともに、液中のご
みをフイルターで過しておくことが望ましい。Next, as shown in FIG. 2, an ultraviolet-curable resin liquid (3) having a flow rate of several times or more the amount of resin to be applied is caused to flow down from a flow-down device (4) installed above the slope of the Fresnel lens mold (1).
As the UV-curable resin used at this time, polyester acrylate, epoxy acrylate, polyurethane acrylate and the like are used, and the viscosity at the time of falling is preferably in the range of 10 to 80 cps, and the transparency after curing is also preferable. Is desirable. When the temperature of the resin liquid is low and the viscosity is high, it is desirable to preheat the resin liquid to adjust the viscosity. At this time, it is desirable that the ultraviolet-curable resin liquid (3) be sufficiently defoamed in advance, and that dust in the liquid be removed by a filter.
第２図の状態で樹脂液が流下する最初の瞬間に型の溝
の内部に、気泡が生じることがあるが、連続的に樹脂液
を流下していくと気泡は液の表面に浮上し樹脂液と共に
流し出すことができる。また、本発明では気泡と同時に
型に付着したごみやほこりも一緒に流し落すことができ
る利点がある。なお、このとき余剰の紫外線硬化型樹脂
液（３）は樹脂受け（５）から回収し再度、脱泡、過
してリサイクル使用するとよい。At the first moment when the resin liquid flows down in the state shown in FIG. 2, bubbles may be generated inside the groove of the mold, but when the resin liquid flows down continuously, the bubbles float on the surface of the liquid and the resin flows. Can be flushed out with liquid. Further, in the present invention, there is an advantage that dirt and dust attached to the mold can be washed off together with the bubbles. At this time, the surplus ultraviolet-curable resin liquid (3) may be recovered from the resin receiver (5), defoamed, passed again, and recycled.
紫外線硬化型樹脂液（３）の流下が終了した後、第３
図に示すように、樹脂液の流下を止めたまた、数秒から
数分間傾斜を保つたままで放置し、金型上の余分な樹脂
液を流し出したのち、樹脂液の厚さが一定になるように
レンズシート型（１）の傾斜を水平にもどす。After the flow of the ultraviolet-curable resin liquid (3) is completed, the third
As shown in the figure, the flow of the resin liquid was stopped.Also, the resin liquid was allowed to stand for a few seconds to several minutes, and the excess resin liquid on the mold was poured out. As described above, the inclination of the lens sheet mold (1) is returned to the horizontal.
レンズシート型（１）上の樹脂膜の厚さが、ほぼ一定
になつたところで、第４図のように上方から透明基材
（２）を静かに載せる。このとき中心部から周辺部へと
軽く圧力がかかるよう透明基材（２）の四隅を持ち上げ
た状態で静かに載せることが望ましいが、レンズシート
型（１）上の紫外線硬化型樹脂液（３）の厚さが0.5mm
程度以上ある場合には、透明基材（２）の片端を型に接
触させた状態で透明基材（２）を傾斜させつつ片側から
重ね合わせてもかまわない。When the thickness of the resin film on the lens sheet mold (1) becomes substantially constant, the transparent substrate (2) is gently placed from above as shown in FIG. At this time, it is desirable to place the transparent substrate (2) gently while lifting the four corners so that light pressure is applied from the center to the periphery. However, the ultraviolet curable resin liquid (3) on the lens sheet mold (1) is preferably used. ) Is 0.5mm thick
In the case where the transparent substrate (2) has a degree or more, the transparent substrate (2) may be overlapped from one side while tilting the transparent substrate (2) in a state where one end of the transparent substrate (2) is in contact with the mold.
以上の工程を経ることにより、レンズシート型（１）
上の紫外線硬化型樹脂液（３）に気泡を巻き込むことな
く透明基材（２）を重ねることができる。そのあと、第
５図のように、透明基材（２）の上から紫外線を照射
（５）し硬化させ、硬化後に脱型してレンズシートを取
り出すが、この方法によつて得られたレンズシートは、
透明基材（２）にレンズが一体的に形成されていて、し
かもレンズ部に泡やごみのない優れたものとなる。Through the above steps, the lens sheet mold (1)
The transparent substrate (2) can be stacked without entrapping air bubbles in the above ultraviolet curing resin liquid (3). Then, as shown in FIG. 5, the transparent substrate (2) is irradiated with ultraviolet rays (5) from above to cure it, and after curing, the mold is removed and the lens sheet is taken out. The sheet is
The lens is formed integrally with the transparent substrate (2), and the lens portion is excellent without bubbles and dust.
なお、レンズシート型（１）と透明基材（２）を重ね
る際には、型の傾斜を保ち余剰の樹脂を流しだす工程を
省略して、レンズシート型（１）上に紫外線硬化型樹脂
液（３）を余剰に残留させたまま透明基材（２）を重ね
たのち、透明基材（２）を加圧して、型の一辺または四
辺全てに余剰樹脂液を漏出させて、紫外線硬化型樹脂液
層の厚さを規定してもよい。When the lens sheet mold (1) and the transparent substrate (2) are overlapped, the step of keeping the mold inclined and pouring out excess resin is omitted, and the ultraviolet curable resin is placed on the lens sheet mold (1). After laminating the transparent substrate (2) with the liquid (3) remaining excessively, the transparent substrate (2) is pressurized, and the excess resin liquid is leaked to one side or all four sides of the mold, and ultraviolet curing is performed. The thickness of the mold resin liquid layer may be defined.
（実施例） 以下、本発明の実施例を第６図ないし第８図に基づい
て説明する。Embodiment An embodiment of the present invention will be described below with reference to FIGS. 6 to 8.
まず第６図に示すように、板厚2mmで1100×800mmの大
きさの黄銅板表面にフレネルレンズ型面を切削したフレ
ネルレンズ型（10）とこのフレネルレンズ型（10）を収
納しうる浅皿部を備え、一辺の枠（6A）が着脱できると
共に、台下面に傾斜固定を可能とする脚（6B）のついた
架台（６）を用意し、ここにフレネルレンズ型（10）を
セツトした。次に、架台（６）が15゜の傾斜を保つよう
脚（6B）を立てた状態で、枠（6A）を外した一辺が樹脂
受け（５）に接するように枠（６）と樹脂受け（５）を
セツテイングした。First, as shown in FIG. 6, a Fresnel lens mold (10) in which a Fresnel lens mold surface is cut on the surface of a brass plate having a thickness of 2 mm and a size of 1100 × 800 mm, and a shallow surface capable of storing the Fresnel lens mold (10). Prepare a base (6) with a dish, a frame (6A) on one side that can be attached and detached, and legs (6B) that can be fixed on the bottom of the table, and a Fresnel lens type (10) set here. did. Next, with the legs (6B) standing upright so that the gantry (6) maintains a 15 ° inclination, the frame (6) and the resin holder (5) are so positioned that one side from which the frame (6A) has been removed is in contact with the resin receiver (5). (5) was set.
紫外線硬化型樹脂液（30）の流下装置としてステンレ
ス管（外径約20mm）に幅1mmの溝を切削した流下装置
（４）を準備し、同装置に紫外線硬化型樹脂液（30）の
送液用に大同メタル社製「WP2040型」ギアポンプと、ラ
インフイルターとして東洋紙製「TCW10RSSフイルタ
ー」とを接続し、毎分40で紫外線硬化型樹脂液（30）
を流下させた。このとき用いた紫外線硬化型樹脂液（3
0）の組成は次の通りである。As a device for flowing the UV-curable resin liquid (30), a flow-down device (4) prepared by cutting a 1 mm wide groove in a stainless steel pipe (outer diameter about 20 mm) is prepared, and the UV-curable resin liquid (30) is sent to the same device. Connect a Daido Metal “WP2040” gear pump for liquid and a Toyo Paper “TCW10RSS filter” as a line filter, and UV curable resin liquid at 30 per minute (30)
Was allowed to flow down. The UV-curable resin liquid (3
The composition of 0) is as follows.
＊三菱レイヨン社製ウレタンアクリレート「UK−6038」
60重量％ ＊三菱レイヨン社製ヒドロキシエチルアクリレート「ア
クリエステルHO」 40重量％ ＊ベンゾフエノン（光硬化触媒）３重量％（上記２つの
モノマーの和に対して） 約１分間、紫外線硬化型樹脂液（30）を流下したの
ち、約20秒間放置してから、脚（6B）を外し傾斜を水平
に戻した。* Urethane acrylate “UK-6038” manufactured by Mitsubishi Rayon Co., Ltd.
60% by weight * Hydroxyethyl acrylate "Acryester HO" manufactured by Mitsubishi Rayon Co., Ltd. 40% by weight * 3% by weight of benzophenone (photocuring catalyst) (based on the sum of the above two monomers) about 1 minute, UV curable resin liquid ( After flowing down 30), it was left for about 20 seconds, and then the legs (6B) were removed and the inclination was returned to horizontal.
次に、第７図のように、フレネルレンズ型（10）とほ
ぼ等しい大きさの透明基材（20）として三菱レイヨン社
製「アクリライト＃000、3mm厚」（紫外線吸収剤を含ま
ないもの）を、透明基材（20）とフレネルレンズ型（1
0）上の樹脂液（30）の間に気泡が入らないよう中心部
から静かにのせたのち、透明基材（20）の上方より、80
W/cmの照射強度のウエスタンクオーツ社製紫外線ランプ
（７）で照射して硬化させた。こののち脱型して取り出
したところ、泡のない第８図のようなフレネルレンズを
得ることができた。Next, as shown in FIG. 7, "Acrylite # 000, 3 mm thick" manufactured by Mitsubishi Rayon Co., Ltd. (without an ultraviolet absorber) was used as a transparent base material (20) having a size substantially equal to the Fresnel lens mold (10). ), Transparent substrate (20) and Fresnel lens type (1
0) After gently placing it from the center so that air bubbles do not enter between the upper resin liquid (30), push it up from above the transparent substrate (20).
Irradiation was carried out with an ultraviolet lamp (7) manufactured by Western Quartz Co., Ltd. having an irradiation intensity of W / cm to cure. Thereafter, when the mold was removed and taken out, a Fresnel lens having no bubbles as shown in FIG. 8 could be obtained.
（発明の効果） 本発明は以上詳述した如き構成からなるものであるか
ら、透明基材上に紫外線硬化型樹脂層によつて気泡、ご
みの発生のないレンズが形成された性能のよいレンズシ
ートを比較的小規模な設備で効率よく製作することがで
き、これによつてレンズシートの生産コストを引き下げ
ることができるという利点を有している。(Effects of the Invention) Since the present invention has the configuration as described in detail above, a lens with good performance in which a lens free of bubbles and dust is formed on a transparent substrate by an ultraviolet-curable resin layer. There is an advantage that the sheet can be manufactured efficiently with relatively small-scale equipment, and thereby the production cost of the lens sheet can be reduced.
第１図ないし第５図は本発明の概略的な工程を示す断面
図、第６図ないし第８図は本発明の実施例の工程を示す
もので、第６図はレンズシート型を含む架台を示す斜視
図、第７図は紫外線照射時の断面図、第８図は得られた
フレネルレンズの断面図である。 （１）……レンズシート型 （２）……透明基材 （３）……紫外線硬化樹脂液1 to 5 are sectional views showing schematic steps of the present invention, FIGS. 6 to 8 show steps of an embodiment of the present invention, and FIG. 6 is a mount including a lens sheet type. FIG. 7 is a cross-sectional view at the time of ultraviolet irradiation, and FIG. 8 is a cross-sectional view of the obtained Fresnel lens. (1) ... Lens sheet type (2) ... Transparent substrate (3) ... Ultraviolet curable resin liquid
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 ＦＩ Ｇ０２Ｂ 3/08 Ｇ０２Ｂ 3/08 // Ｂ２９Ｌ 11:00 (58)調査した分野(Int.Cl.6，ＤＢ名) B29C 41/00 - 41/52 B29C 33/00 - 33/76 B29L 11:00 B29D 11/00 G02B 3/00 - 5/32──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 6 identification symbol FI G02B 3/08 G02B 3/08 // B29L 11:00 (58) Field surveyed (Int.Cl. 6 , DB name) B29C 41 / 00-41/52 B29C 33/00-33/76 B29L 11:00 B29D 11/00 G02B 3/00-5/32
Claims (2)
展延し、この上面に透明基材を載置し、この状態で紫外
線を照射してレンズシートを製造する方法において、上
記レンズシート型を水平面に対し５〜30゜傾斜させて紫
外線硬化型樹脂液を流下、展延させ、しかるのち紫外線
を照射することを特徴とするレンズシート製造方法。1. A method of manufacturing a lens sheet by spreading an ultraviolet-curable resin liquid on a lens sheet mold, placing a transparent substrate on the upper surface, and irradiating ultraviolet rays in this state to produce a lens sheet. A method for producing a lens sheet, characterized in that a mold is inclined at 5 to 30 ° with respect to a horizontal plane, an ultraviolet-curable resin liquid is allowed to flow down and spread, and then ultraviolet rays are irradiated.
を使用することを特徴とする請求項第１項記載のレンズ
シート製造方法。2. The method according to claim 1, wherein an ultraviolet curable resin having a viscosity of 10 to 80 cps is used.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP29539389A JP2770058B2 (en) | 1989-03-23 | 1989-11-14 | Manufacturing method of lens sheet |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1-71345 | 1989-03-23 | ||
| JP7134589 | 1989-03-23 | ||
| JP29539389A JP2770058B2 (en) | 1989-03-23 | 1989-11-14 | Manufacturing method of lens sheet |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0315510A JPH0315510A (en) | 1991-01-23 |
| JP2770058B2 true JP2770058B2 (en) | 1998-06-25 |
Family
ID=26412453
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP29539389A Expired - Fee Related JP2770058B2 (en) | 1989-03-23 | 1989-11-14 | Manufacturing method of lens sheet |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2770058B2 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111103640B (en) * | 2019-11-27 | 2021-11-12 | 诚瑞光学(常州)股份有限公司 | Fresnel lens metal mold manufacturing method |
-
1989
- 1989-11-14 JP JP29539389A patent/JP2770058B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0315510A (en) | 1991-01-23 |
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