JP3544587B2 - Method for manufacturing composite optical element - Google Patents

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method for manufacturing a composite optical element in which a resin layer is mounted on an optical element substrate.
[0002]
[Prior art]
As a prior art, there is JP-A-4-144718. In this method, when the mold and the cured resin layer are separated from each other, a load is applied to a portion (portion outside the effective diameter) which is not related to the optical performance of the resin layer surface, so that the mold and the resin layer can be easily separated. However, the shape of the portion (the portion within the effective diameter) related to the optical performance of the resin layer is symmetric with respect to the central axis.
[0003]
[Problems to be solved by the invention]
However, in the method of the prior art, when the mold and the cured resin layer are peeled off, a load is applied to a portion not related to the optical performance of the resin layer. Need to be somewhat larger. If the part to which the load is applied is narrow, stress is concentrated locally in the radial direction, so that the resin part within the effective diameter is affected by the deformation of the resin part outside the effective diameter, and the resin layer surface has the desired optical surface shape. The problem that does not become. In addition, a problem that the optical element base material is damaged may occur at the same time.
[0004]
Therefore, if the width of the portion to which a load is applied is increased, the diameter of the composite optical element itself naturally increases. As a matter of course, products using the composite optical element manufactured here also become large.
[0005]
However, in the field of cameras and the like, competition for miniaturization of products is fierce, and it is not desirable to increase parts that are not directly related to performance. In particular, a product such as a compact camera, which is one of the merits of reducing the size itself, is a fatal problem that the attractiveness is significantly impaired.
[0006]
The present invention has been made in view of the above-described problems of the related art, and has a portion for applying a load when the mold and the cured resin layer are peeled off outside the effective diameter of the resin layer related to optical performance. It is an object of the present invention to provide a method of manufacturing a composite optical element capable of manufacturing a composite optical element having a small diameter, which does not need to be provided.
[0007]
[Means for Solving the Problems]
In order to solve the above problems, the present invention has the following configuration.
The invention according to claim 1 is to supply an energy-curable resin to a molding surface of an optical element substrate, and to make the mold and the optical element substrate relatively close to each other to spread out the resin, thereby forming a mold and an optical element. After forming a desired resin layer between the base material, the resin layer is cured by irradiating energy, and then the resin to be formed in the method of manufacturing a composite optical element in which the cured resin layer and the mold are separated. The portion of the layer related to the optical performance has a non-axially symmetric shape with respect to the central axis of the optical element substrate molding surface, and the resin layer is effective around a point on the central axis of the optical element substrate molding surface. A load is applied to a portion of the circle having the maximum value of the diameter, which is not related to the optical performance, to separate the mold from the cured resin layer.
[0008]
According to a second aspect of the present invention, in the configuration of the first aspect, the portion irrelevant to the optical performance is a resin layer.
[0009]
According to a third aspect of the present invention, in the configuration of the first aspect, the portion irrelevant to the optical performance is an optical element substrate. .
[0010]
The operation of claim 1 will be described.
At present, since a generally used film is rectangular, a light beam reaching the film surface does not necessarily have to be axially symmetric about the central axis of the optical element substrate. Therefore, the effective diameter itself related to the optical performance of the composite optical element does not necessarily have to be axially symmetric.
[0011]
However, glass is often used as the base material of the composite optical element, but it is more costly to process glass into a non-axially symmetric shape than to process it into an axially symmetric shape. In the manufacture of a composite optical element, the resin placed on the base material is pressed with a mold to form a resin layer. Therefore, when the base material has a non-axisymmetric shape, operations such as positioning during manufacture are performed. Is not preferable because the number of operations increases. On the other hand, the resin layer placed on the base material can have a free shape to some extent. Once the mold for forming the resin layer is manufactured, it can be used for a long period of time, so that the cost is almost negligible compared to the case where the base material is processed into a non-axisymmetric shape.
[0012]
Therefore, if a portion related to optical performance is placed on a non-axially symmetric resin layer on a center axis symmetric base material, a portion unrelated to optical performance when the mold and the cured resin layer are peeled off. By applying a load to the mold, the mold and the resin layer can be easily peeled off by the same means as in the prior art.
[0013]
In the configuration of claim 2, the resin layer itself has an axially symmetric shape, and a portion related to the optical performance of the resin layer has a non-axially symmetric shape, so that immediately after the curing of the resin layer is completed. First, the mold and the resin layer are separated from each other in a portion of the resin layer that is not related to the optical performance, and then the mold is separated from the composite optical element by applying a load to the resin layer from which the mold has been separated.
[0014]
Further, in the configuration of claim 3, the resin layer itself has a non-axisymmetric shape, and after the resin layer is completely cured, a load is applied to a portion of the base material where the resin layer is not formed as it is. And the composite optical element are separated.
[0015]
BEST MODE FOR CARRYING OUT THE INVENTION
[First Embodiment of the Invention]
First Embodiment A first embodiment of the present invention will be described with reference to FIGS.
As shown in FIG. 1, a required amount of resin 5 is discharged onto an optical element substrate (hereinafter, referred to as a substrate) 2 made of glass having concave surfaces on both sides. The radius of curvature of the molding surface (the surface on which the resin layer is placed) of the substrate 2 is 100 mm, the radius of curvature of the non-molding surface (the surface on which the resin layer is not placed) is 80 mm, and the outer diameter is 25 mm. Also, it is assumed that the required amount of the resin 5 is obtained in advance.
[0016]
On the other hand, the mold 1 used in the present embodiment has an optical surface (a surface that presses the resin layer) 1a for forming a desired resin layer surface on the substrate 2, and the central axis is And is held movably up and down with the same central axis. The shape (outline) of the outer peripheral portion of the optical surface 1a of the mold 1 is non-axially symmetric, and the point on the central axis of the optical surface 1a of the mold 1 is defined as an origin on an xy plane perpendicular to the central axis. When the points on the outer peripheral portion of the optical surface 1a of the mold 1 are moved in parallel with the central axis, as shown in FIG. Is a straight line 1c having a constant y coordinate connecting the end points of the two arcs 1b.
[0017]
Next, a step of forming the resin layer 3 having a desired thickness by spreading the resin 5 on the optical surface 1a by lowering the mold 1 to approach the substrate 2 will be described.
The portion related to the optical performance of the resin layer 3 formed on the base material 2 is a circular arc having a diameter of 24 mm in a range of 45 degrees above and below the x axis, and the other portion has a constant y coordinate connecting two end points. Area surrounded by the straight line. When the resin 5 is pressed down by lowering the mold 1, the resin 5 is shown in FIG. 3 (a cross-sectional view including the central axis viewed from the x-axis direction) and the figure until immediately before the resin 5 protrudes from the outer peripheral portion of the optical surface 1 a of the mold 1. As shown in FIG. 4 (a cross-sectional view including the central axis viewed from the y-axis direction), the resin 5 spreads concentrically on the base material 2. When the mold 1 is further lowered, the resin 5 protrudes from the linear 1c-shaped portion of the optical surface 1a of the mold 1. When the resin 5 protrudes from the outer peripheral portion of the optical surface 1a of the mold 1 (the surface of the protruding portion is referred to as 5a), the speed at which the resin 5 spreads in the radial direction is different from that of the resin 5 which is still pressed, As shown in FIG. 5 (cross-sectional view including the central axis viewed from the x-axis direction) and FIG. 6 (cross-sectional view including the central axis viewed from the y-direction), the shape of the resin 5 on the base material 2 is not concentric. Disappears. That is, since the portion 5a of the resin 5 protruding from the outer peripheral portion of the optical surface 1a of the mold 1 is not subjected to the pressure caused by lowering the mold 1, it hardly spreads in the radial direction but spreads in the vertical direction. . Then, the mold 1 is lowered until the resin layer 3 on the central axis has a desired thickness, and the desired resin layer 3 is formed. At this time, as shown in FIG. 7, the amount of the resin 5 to be discharged onto the base material 2 needs to be adjusted in advance so that the resin 5 can be spread over the entire area related to the optical performance. FIG. 7 is a plan view of the resin layer 3 as viewed from the direction parallel to the central axis of the substrate 2.
[0018]
Next, in this state, the resin layer 3 is cured by irradiating ultraviolet rays from below the substrate 2 by means (not shown). Then, when the energy irradiation is completed, a close contact body in which the mold 1, the base material 2, and the cured resin layer 3 are integrated is formed.
[0019]
Next, as shown in FIG. 8, when the contact body is lifted, the peeling member 4 previously provided above the portion of the base material 2 where the resin layer 3 is not formed becomes the surface of the base material 2. 2a. Then, the load is first concentrated on the portion of the surface 2 a of the substrate 2 where the peeling member 4 is in contact, and then the load is dispersed throughout the substrate 2. Then, as the contact body continues to rise, the resin layer 3 is separated from the mold 1 as shown in FIG. 9, and the composite optical element 6 in which the base material 2 and the resin layer 3 are integrated is obtained. FIG. 10 shows a view of the manufactured composite optical element 6 as viewed from above.
[0020]
According to the manufacturing method of the embodiment of the present invention, easy separation of the mold 1 and the cured resin layer 3 can be realized only by making the substrate 2 slightly larger than the maximum effective diameter.
[0021]
[Embodiment 2]
Embodiment 2 of the present invention will be described with reference to FIGS.
As shown in FIG. 11, a required amount of resin 15 is discharged onto a glass substrate 12 having concave surfaces on both sides. The radius of curvature of the molding surface (the surface on which the resin layer is placed) of the substrate 12 is 100 mm, the radius of curvature of the non-molding surface (the surface on which the resin layer is not placed) is 80 mm, and the outer diameter is 42 mm. It is also assumed that the required amount of the resin 15 is determined in advance.
[0022]
On the other hand, as shown in FIGS. 13 and 14, the mold 11 used in the present embodiment is configured by combining an A mold 11a and a B mold 11b which are relatively movable in the axial direction. The end face of the mold 11b is formed on the mold optical surface that presses the resin 15 with no step, and has an axially symmetric shape with a diameter of 42 mm. That is, when a point on the center axis of the mold optical surface of the mold 11 is set as the origin, the center axis is set as the z axis, and the x and y axes are set in directions perpendicular to the center axis and perpendicular to each other, as shown in FIG. As described above, an A-type 11a for pressing a portion related to optical performance including a portion related to optical performance and a B-type 11b for pressing only a portion unrelated to optical performance at a position at a distance of 19 mm from the x-axis, which are vertically movable with respect to each other. Each of the A-type 11a and the B-type 11b has an optical surface for forming a desired resin layer surface, and the center axis of the mold 11 is the same as the center axis of the base material 12. .
[0023]
Next, a method for manufacturing the composite optical element will be described.
First, as shown in FIG. 13, the mold 11 is lowered to approach the base material 12 with no step at the boundary between the optical surface of the A type 11a and the optical surface of the B type 11b, so that The resin 15 is spread and the lowering of the mold 11 is stopped at a position where the resin layer 13 having a desired thickness is formed.
[0024]
Next, in this state, the resin layer 13 is cured by irradiating ultraviolet rays from below the substrate 12 by means (not shown). Then, when the energy irradiation is completed, a close contact body in which the mold 11, the base material 12, and the cured resin layer 13 are integrated is formed.
[0025]
Next, as shown in FIG. 14, the B-type 11b is lifted, and a portion of the B-type 11b irrelevant to the optical performance is peeled off from the close contact body. At this time, the area of the optical surface where the B type 11b is in close contact with the resin layer 13 is smaller than the area of the optical surface where the A type 11a is in close contact with the resin layer 13, and the A type 11a and the resin layer 13 are Since they are fixed to each other, the B-type 11b can be easily separated from the surface 13a of the resin layer 13. Then, after the B-type 11b is peeled off from the surface of the resin layer 13, the peeling member 14 previously provided outside the effective diameter of the base material 12 is removed from the surface of the resin layer 13 where the B-type 11b is peeled off. 13a.
[0026]
Next, when the adhered body of the A-type 11a, the resin layer 13 and the base material 12 is raised, the peeling member 14 comes into contact with the surface 13a of the resin layer 13, and first, the peeling member 14 on the surface 13a of the resin layer 13 is formed. The load is concentrated on the portion where the member 14 contacts, and thereafter the load is dispersed from the resin layer 13 to the entire base material 12. Then, if the contact body continues to rise, the composite optical element 16 in which the base material 12 and the resin layer 13 are integrated from the A type 11a is peeled off as shown in FIG. The surface 13a of the resin layer 13 of the manufactured composite optical element 16 has traces of boundaries between the optical surface of the A-type 11a and the optical surface of the B-type 11b, which form the mold optical surface of the mold 11, and the surface for separation. Although traces of pressing by the member 14 remain, there is no problem in performance since this portion is not related to optical performance.
[0027]
According to the manufacturing method of the embodiment of the present invention, easy separation of the mold 11 and the cured resin layer 13 can be realized only by making the base material 12 slightly larger than the maximum effective diameter.
[0028]
【The invention's effect】
As described above, according to the method for manufacturing a composite optical element according to claims 1 to 3 of the present invention, the optical element base is only slightly larger than the maximum effective diameter related to the optical performance of the resin layer. In addition, it is possible to realize easy separation between the mold and the cured resin layer, and to manufacture a composite optical element capable of responding to a demand for miniaturization of a product.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing one step of Embodiment 1 of the present invention, showing a state where a resin is discharged onto a base material.
FIG. 2 is a plan view showing an optical surface of a mold used in the first embodiment of the present invention.
FIG. 3 is a cross-sectional view illustrating one step of the first embodiment of the present invention, as viewed from the direction of the x-axis in FIG. 2;
FIG. 4 is a cross-sectional view illustrating one step of the first embodiment of the present invention, as viewed from the direction of the y-axis in FIG. 2;
FIG. 5 is a cross-sectional view showing one step of the first embodiment of the present invention, as viewed from the direction of the x-axis in FIG. 2;
FIG. 6 is a cross-sectional view showing one step of the first embodiment of the present invention, as viewed from the direction of the y-axis in FIG. 2;
FIG. 7 is a plan view showing a resin layer formed on a base material according to the first embodiment of the present invention.
FIG. 8 is a cross-sectional view showing one step of the first embodiment of the present invention, showing a state in which the resin layer and the mold are separated.
FIG. 9 is a cross-sectional view showing one step of the first embodiment of the present invention, and shows a state where the mold and the composite optical element are separated.
FIG. 10 is a plan view showing a composite optical element manufactured according to the first embodiment of the present invention.
FIG. 11 is a cross-sectional view showing one step of Embodiment 2 of the present invention, and shows a state where a resin is discharged onto a base material.
FIG. 12 is a plan view showing an optical surface of a mold used in Embodiment 2 of the present invention.
FIG. 13 is a cross-sectional view showing one step of Embodiment 2 of the present invention, showing a state where a resin layer is formed.
FIG. 14 is a cross-sectional view showing one step of Embodiment 2 of the present invention, and shows a state in which one mold is separated from a resin.
FIG. 15 is a cross-sectional view showing one step of Embodiment 2 of the present invention, and shows a state where the mold and the composite optical element are separated.
[Explanation of symbols]
1,11 Mold 2,12 Optical element substrate 3,13 Resin layer 4,14 Peeling member 5,15 Resin 6,16 Composite optical element

Claims (3)

An energy-curable resin is supplied to the optical element substrate molding surface, and the resin is spread out by relatively bringing the mold and the optical element substrate closer to each other, so that the resin is spread between the mold and the optical element substrate. After the resin layer is formed, the resin layer is cured by irradiation of energy, and then the cured resin layer and the mold are separated from each other. Is asymmetrical with respect to the central axis of the optical element substrate molding surface, and the maximum effective diameter of the resin layer centered on a point on the central axis of the optical element substrate molding surface is defined as the diameter. A method for manufacturing a composite optical element, comprising applying a load to a portion irrelevant to optical performance in a circle defined above and separating the mold from the cured resin layer. 2. The method according to claim 1, wherein the portion irrelevant to the optical performance is a resin layer. 2. The method according to claim 1, wherein the portion irrelevant to the optical performance is an optical element substrate.

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