JP4560318B2 - Lens press molding method - Google Patents
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- JP4560318B2 JP4560318B2 JP2004096581A JP2004096581A JP4560318B2 JP 4560318 B2 JP4560318 B2 JP 4560318B2 JP 2004096581 A JP2004096581 A JP 2004096581A JP 2004096581 A JP2004096581 A JP 2004096581A JP 4560318 B2 JP4560318 B2 JP 4560318B2
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- 238000000465 moulding Methods 0.000 title claims description 28
- 238000000034 method Methods 0.000 title claims description 19
- 239000012778 molding material Substances 0.000 claims description 36
- 238000003825 pressing Methods 0.000 claims description 7
- 239000000758 substrate Substances 0.000 claims description 4
- 239000000047 product Substances 0.000 description 11
- 230000003287 optical effect Effects 0.000 description 9
- 239000010408 film Substances 0.000 description 5
- 238000010835 comparative analysis Methods 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 239000004925 Acrylic resin Substances 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000003491 array Methods 0.000 description 2
- 238000004891 communication Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000002834 transmittance Methods 0.000 description 1
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- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
本発明は、レンズのプレス成形方法に関する。 The present invention relates to a lens press molding method.
本発明は、特にマイクロレンズおよびマイクロレンズアレイの光学機能面を有する光学素子や分析用素子のプレス成形方法に関する。 The present invention particularly relates to a press molding method of an optical element or an analytical element having an optical functional surface of a microlens and a microlens array.
マイクロレンズアレイは液晶プロジェクター、デジタルカメラ、デジタルビデオ、スキャナー、光通信用コネクション、レーザービームコリメーティング／シェイピング、光拡散板、立体ディスプレー、光計測等に広く用いられ手いる。近年これらのマイクロレンズアレイの寸法精度の向上が望まれている。 Microlens arrays are widely used for liquid crystal projectors, digital cameras, digital videos, scanners, optical communication connections, laser beam collimating / shaping, light diffusion plates, stereoscopic displays, optical measurement, and the like. In recent years, it has been desired to improve the dimensional accuracy of these microlens arrays.
従来、マイクロレンズを製造する場合、効率や透過率等のパラメータより光学設計を行い、この設計結果に基づいて金型を作製し、作成された金型を使用してマイクロレンズを成形していた。成形品の寸法精度を向上するための手順は、従来以下のものであった。すなわち、成形材料の金型形状に対する充填率を100％に近づけるようにする。つぎに、成形品の収縮、成形歪の補正を金型で行い成形品の寸法精度を向上させていた。光学素子のプレス成形における充填率（転写率）を高める従来の技術として、たとえば、特許文献１に開示されたものがある。
Conventionally, when manufacturing a microlens, optical design is performed based on parameters such as efficiency and transmittance, a mold is manufactured based on the design result, and the microlens is molded using the created mold. . The procedure for improving the dimensional accuracy of a molded product has been conventionally as follows. That is, the filling rate with respect to the mold shape of the molding material is made close to 100%. Next, the dimensional accuracy of the molded product is improved by correcting the shrinkage and molding distortion of the molded product with a mold. As a conventional technique for increasing the filling rate (transfer rate) in press molding of an optical element, for example, there is one disclosed in
従来、プレス成形によりレンズを製造する際に、金型形状や成形厚み、プレス圧力によってはレンズの頂点部に凹みが発生することがあった。特にガラス基板上に樹脂成形薄膜層を設けて成形する場合にこの傾向は顕著であった。従来技術においては、上記のように、成形材料の金型形状に対する充填率を100％に近づけることにより、レンズの頂点部に生じる凹みの問題を解決しようとしていた。 Conventionally, when a lens is manufactured by press molding, a dent may occur at the apex of the lens depending on the mold shape, molding thickness, and pressing pressure. This tendency was particularly remarkable when a resin molded thin film layer was formed on a glass substrate. In the prior art, as described above, an attempt has been made to solve the problem of dents generated at the apex of the lens by bringing the filling rate of the molding material into the mold shape close to 100%.
しかしながら、プレス成形において、成形材料の金型形状に対する充填率を100％に近づけようとすると過大なプレス圧力が必要となり装置が大型化するという問題点があった。また、成形品の離型性が悪くなり、離型性を補うために離型膜を設けると、成形品の寸法精度が低下するという問題点があった。 However, in press molding, if the filling rate of the molding material with respect to the mold shape is to be close to 100%, there is a problem that an excessive press pressure is required and the apparatus is enlarged. Further, the mold release property of the molded product is deteriorated, and when a release film is provided to supplement the mold release property, there is a problem that the dimensional accuracy of the molded product is lowered.
したがって、過大なプレス圧力を必要とせず、離型膜により成形品の寸法精度を低下させずに、レンズの頂点部に凹みを生じさせないプレス成形方法に対する大きなニーズがある。 Therefore, there is a great need for a press molding method that does not require an excessive press pressure, does not reduce the dimensional accuracy of the molded product by the release film, and does not cause a depression at the apex of the lens.
本発明による、金型によるレンズのプレス成形方法は、レンズの開口半径をｒ、金型のレンズ頂点部の深さをｄ、成形材の成形厚みをｔとし、ｒ／ｄをｘ、ｔ／ｄをｙとしたときにｘ＞０において
ｙ≧-0.013ｘ２＋0.77ｘ
を満たす範囲において、金型に対する成形材料の充填率が９５％以下となるようにする。
According to the present invention, a lens press molding method using a mold is such that the opening radius of the lens is r, the depth of the lens apex of the mold is d, the molding thickness of the molding material is t, and r / d is x, t / When d is y and x> 0, y ≧ −0.013x 2 + 0.77x
In a range that satisfies the condition, the filling rate of the molding material into the mold is set to 95% or less.
上記の数式を満たすことにより、レンズの頂点部の凹みを生じることはない。また、充填率を９５％以下とすることにより、プレス圧力は、充填率が１００％の場合の約７０％以下となる。したがって、過大なプレス圧力を必要とせず、離型膜により成形品の寸法精度を低下させることもない。 Satisfaction of the above formula does not cause a depression at the apex of the lens. Further, by setting the filling rate 95% or less, pressing pressure, it follows that Do about 70% when the filling rate is 100%. Therefore, an excessive pressing pressure is not required, and the dimensional accuracy of the molded product is not reduced by the release film.
本発明の一実施形態による、金型によるレンズのプレス成形方法は、金型に対する成形材料の充填率が９０％以下となるようにする。 According to one embodiment of the present invention, a lens press molding method using a mold is such that the filling rate of the molding material into the mold is 90% or less.
充填率を９０％以下とすることにより、プレス圧力は、充填率が１００％の場合の約５０％以下となるとなる。したがって、過大なプレス圧力を必要とせず、離型膜により成形品の寸法精度を低下させることもない。 By setting the filling rate to 90% or less, the press pressure becomes about 50% or less when the filling rate is 100%. Therefore, an excessive pressing pressure is not required, and the dimensional accuracy of the molded product is not lowered by the release film.
本発明の一実施形態による、金型によるレンズのプレス成形方法は、金型に対する成形材料の充填率が８０％以下となるようにする。 According to one embodiment of the present invention, a lens press molding method using a mold is such that the filling rate of the molding material into the mold is 80% or less.
充填率を８０％以下とすることにより、プレス圧力は、充填率が１００％の場合の約２０％以下となるとなる。したがって、過大なプレス圧力を必要とせず、離型膜により成形品の寸法精度を低下させることもない。 By setting the filling rate to 80% or less, the press pressure becomes about 20% or less when the filling rate is 100%. Therefore, an excessive pressing pressure is not required, and the dimensional accuracy of the molded product is not lowered by the release film.
本発明の一実施形態による、金型によるレンズのプレス成形方法は、プレス圧力を操作することにより、金型に対する成形材料の充填率を制御する。 According to one embodiment of the present invention, a method for press-molding a lens using a mold controls the filling rate of a molding material into the mold by manipulating the press pressure.
したがって、金型に対する成形材料の充填率を確実に制御することができる。 Therefore, it is possible to reliably control the filling rate of the molding material into the mold.
本発明の一実施形態による、金型によるレンズのプレス成形方法は、充填率から充填形状を予測して金型形状を決める。 According to an embodiment of the present invention, a lens press molding method using a mold determines a mold shape by predicting a filling shape from a filling rate.
したがって、所望のレンズ形状を実現することができる。 Therefore, a desired lens shape can be realized.
本発明の一実施形態による、金型によるレンズのプレス成形方法は、成形材料の厚みが１から500μｍである。 According to one embodiment of the present invention, a lens press molding method using a mold has a molding material thickness of 1 to 500 μm.
本発明の一実施形態による、金型によるレンズのプレス成形方法は、レンズのプレス成形温度で軟化変形しない光透過基板上に成形材料を設けている。 According to one embodiment of the present invention, a lens press-molding method using a mold is provided with a molding material on a light-transmitting substrate that does not soften and deform at the lens press-molding temperature.
最初に、金型（１）と成形材料（２）との関係を図１に示す。図１において、ｒはレンズの開口半径、ｄは金型のレンズ頂点部の深さ、ｔは成形材の成形厚みを表す。 First, the relationship between the mold (1) and the molding material (2) is shown in FIG. In FIG. 1, r represents the lens opening radius, d represents the depth of the lens apex of the mold, and t represents the molding thickness of the molding material.
ガラス基板上にアクリル樹脂を成形材料として厚みを50μｍにし、曲面シリンドリカルマイクロレンズアレイのプレス成形を行った場合について解析を行った。成形材料の金型形状に対する充填率は、７０％とした。なお、充填率を高めても、成形材料の充填形状（凹みの有無、平坦の形状）は、ほぼ一定である。金型形状と成形材料の厚みによる充填形状の解析結果を表１に示す。
表１において、ｒはレンズの開口半径、ｄは金型のレンズ頂点部の深さ、ｔは成形材の成形厚みを表す。また、表１の結果からｒ／ｄをｘ、ｔ／ｄをｙとしたときにｘ＞０において
ｙ≧-0.013ｘ２＋0.77ｘ (1)
を満たす場合に凹みが生じないことがわかる。
In Table 1, r represents the lens opening radius, d represents the depth of the lens apex of the mold, and t represents the molding thickness of the molding material. From the results of Table 1, when r / d is x and t / d is y, x> 0
y ≧ -0.013x 2 + 0.77x (1)
It can be seen that there is no dent when satisfying.
比較解析実施例としてr/d=xが3.0、t/d=yが1の場合の、成形材料（２）の金型（１）に対する充填の様子を図２に示す。成形材料においてレンズの光学面に対応する部分を３で表す。この場合、
-0.013ｘ２＋0.77ｘ= 2.193
であるので、上記の式（１）は満たされない。図２のように充填率が７０％ではレンズ頂点部が凹形状となっている。凹みがなくなるのは１００％充填された場合のみである。
FIG. 2 shows how the molding material (2) is filled into the mold (1) when r / d = x is 3.0 and t / d = y is 1 as a comparative analysis example. A portion corresponding to the optical surface of the lens in the molding material is represented by 3. in this case,
-0.013x 2 + 0.77x = 2.193
Therefore, the above equation (1) is not satisfied. As shown in FIG. 2, when the filling rate is 70%, the apex of the lens has a concave shape. The dent disappears only when 100% is filled.
さらに別の比較解析実施例としてr/d=xが1.4、t/d=yが1の場合の、成形材料の充填の様子を図２に示す。この場合、
-0.013ｘ２＋0.77ｘ= 1.053
であるので、上記の式（１）は満たされない。図３のように１００％充填されるまでレンズ頂点部が平坦な形状に近くなる。
As another comparative analysis example, FIG. 2 shows a state of filling of the molding material when r / d = x is 1.4 and t / d = y is 1. in this case,
-0.013x 2 + 0.77x = 1.053
Therefore, the above equation (1) is not satisfied. As shown in FIG. 3, the lens apex portion is close to a flat shape until it is 100% filled.
本発明の実施例としてr/dが1.0、t/dが1の場合の、成形材料の充填の様子を図４に示す。この場合、
-0.013ｘ２＋0.77ｘ= 0.757
であるので、上記の式（１）は満たされる。図４のように充填率が８０％でもレンズの頂点部には凹みは生じない。
FIG. 4 shows how the molding material is filled when r / d is 1.0 and t / d is 1 as an embodiment of the present invention. in this case,
-0.013x 2 + 0.77x = 0.757
Therefore, the above equation (1) is satisfied. As shown in FIG. 4, even if the filling rate is 80%, no dent is generated at the apex of the lens.
r/dが1.0、t/dが1の場合において、金型に100％充填するプレス圧力を100％としたときのプレス圧力に対する充填率を解析した結果を表２に示す。この結果を見てわかるとおり約80％の充填を得るためには20％のプレス圧力、約90％の充填を得るためには50％のプレス圧力で済むことがわかる。したがって、充填率を低下させることができれば、プレス圧力は大幅に低下する。
実際にr/dが1.7、t/dが2の金型形状、成形材の厚みで７０％の充填率でアクリル樹脂をプレス成形したところ離型膜がなくとも離型性も良好で凹みのない形状が得られた。 Actually, when the acrylic resin was press-molded with a mold shape of r / d of 1.7 and t / d of 2 and a filling rate of 70% by the thickness of the molding material, the mold release property was good and the dent was not formed. No shape was obtained.
８０％以下の充填率で製品設計できることにより、１００％充填させる場合に比べて２０％の圧力で成形でき成形品の離型性が良くなることや、過大な圧力が必要ないので装置の小型化、金型寿命の延長、金型へのコートが不要になることによる光学面の精度向上の効果が得られる。 The ability product design with less than 80% fill factor, miniaturization of 20 percent and that the releasability of the molded product can be molded is improved by the pressure, there is no need excessive pressure device as compared with the case of filling 100% The effect of improving the accuracy of the optical surface can be obtained by extending the mold life and eliminating the need to coat the mold.
成形材料としては、ポリオレフィン系、ポリカーボネート系、エポキシ系樹脂およびガラスなど、どのような材料にも適用することができる。 The molding material can be applied to any material such as polyolefin, polycarbonate, epoxy resin and glass.
１ 金型
２ 成形材料
３ レンズの光学面
1
Claims (6)
ｘ≦１かつｙ≧１、
ｘ≦２．６かつｙ≧２、または
ｘ≦３．３かつｙ≧３
を満たす範囲において、金型に対する成形材料の、プレス時における充填率が９５％以下となるようにする、レンズのプレス成形方法。 A method for press-molding a lens with a mold, wherein the radius of the lens opening is r, the depth of the apex of the mold is d, the molding thickness of the molding material is t, r / d is x, and t / d is When y
x ≦ 1 and y ≧ 1,
x ≦ 2.6 and y ≧ 2, or
x ≦ 3.3 and y ≧ 3
A lens press-molding method in which a filling ratio of a molding material to a mold is 95% or less within a range satisfying the above.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004096581A JP4560318B2 (en) | 2004-03-29 | 2004-03-29 | Lens press molding method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004096581A JP4560318B2 (en) | 2004-03-29 | 2004-03-29 | Lens press molding method |
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| Publication Number | Publication Date |
|---|---|
| JP2005280065A JP2005280065A (en) | 2005-10-13 |
| JP2005280065A5 JP2005280065A5 (en) | 2007-03-08 |
| JP4560318B2 true JP4560318B2 (en) | 2010-10-13 |
Family
ID=35178962
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2004096581A Expired - Lifetime JP4560318B2 (en) | 2004-03-29 | 2004-03-29 | Lens press molding method |
Country Status (1)
| Country | Link |
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08127032A (en) * | 1994-11-02 | 1996-05-21 | Ricoh Co Ltd | Manufacture of plastic molded product |
| JP2001042104A (en) * | 1999-07-27 | 2001-02-16 | Seiko Epson Corp | Microlens array, its production, master disk for production of the same and display device |
| JP2002062416A (en) * | 2000-08-21 | 2002-02-28 | Canon Inc | Method for manufacturing optical device or method for manufacturing device, and optical system, device for photographing and device for observation having the same |
-
2004
- 2004-03-29 JP JP2004096581A patent/JP4560318B2/en not_active Expired - Lifetime
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH08127032A (en) * | 1994-11-02 | 1996-05-21 | Ricoh Co Ltd | Manufacture of plastic molded product |
| JP2001042104A (en) * | 1999-07-27 | 2001-02-16 | Seiko Epson Corp | Microlens array, its production, master disk for production of the same and display device |
| JP2002062416A (en) * | 2000-08-21 | 2002-02-28 | Canon Inc | Method for manufacturing optical device or method for manufacturing device, and optical system, device for photographing and device for observation having the same |
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| Publication number | Publication date |
|---|---|
| JP2005280065A (en) | 2005-10-13 |
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