JPH07112443A - Composite type molded article and its manufacture and mold - Google Patents

Abstract

PURPOSE:To provide a composite type molded article of which the characteristics such as the surface precision, etc., are not spoiled, and of which the production efficiency is high, and its manufacturing method and its mold. CONSTITUTION:To a mold 3, an active energy beam curing resin 2 and molded article base material 1 are fed, and after clamping the mold 3, an active energy beam is applied to cure the resin 2, and the mold is released. Thus, on the surface of the molded article base material 1, a cured resin layer 1 is joined to form a composite type molded article. For such a manufacturing method, the resin layer 2 is formed by using a mold being equipped with a frame body 4 made of a high polymer of which the inner peripheral shape is smaller than the outer peripheral shape of the molded article base material, on the surface outer peripheral part of the mold 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite molded article such as an aspherical lens, a Fresnel lens, a diffraction grating, etc., in which an active energy ray-curable resin is closely molded on the surface of a glass base material, etc. Regarding the mold.

[0002]

2. Description of the Related Art In recent years, a technique has been developed in which an active energy ray-curing resin is adhered and molded on the surface of a base material such as glass by using a molding die member having a predetermined surface shape. It is used as a manufacturing method for lattices. At the time of this molding, for example, a method of manufacturing an aspherical lens is disclosed in JP-A-64-35401 and JP-A-1-35401.
171932, JP-A-3-13902, JP-A-4-14
It is disclosed in gazettes such as 4718.

An example thereof is shown in FIGS. 25 to 27.
An active energy ray curable resin 22 typified by an ultraviolet curable resin is dropped on the surface of a molding die 23 which is an aspherical mold shown in FIG. 25, and a base material 21 which is a glass spherical lens as shown in FIG. The resin supplied is clamped using some jig not shown in the figure so that the base material lens and the optical axis of the aspherical surface are aligned, and the resin is irradiated with active energy rays so that the resin thickness is constant. After being cured and released from the mold, a composite aspherical lens as shown in FIG. 27 is obtained.

[0004]

However, as a general property of the active energy ray-curable resin, although there are some differences depending on the type, the portion in contact with the air is subjected to curing inhibition by oxygen in the air and is thus activated. Often, even when irradiated with energy rays, it is not completely cured.
In the case of such a mold structure, since the side surface 24 of the active energy ray-curable resin layer 22 is in contact with air, the curing is slower than that inside the resin layer, curing failure occurs, and the surface is sticky forever. It remained in the state.

Therefore, in this state as it is, it causes stains due to bleeding and transfer of the uncured resin which occurs during handling of the lens after molding. Therefore, after the mold is released, a step of wiping the side surface with a solvent is newly added. There is a problem in that it is necessary to newly provide extra steps such as providing or completely curing the side surface of the lens by activating the side surface of the lens in a vacuum with an active energy ray, resulting in an increase in product cost. .

In order to solve the above problems, it is possible to use an active energy ray-curable resin that is not affected by oxygen inhibition. However, this type of resin has a high curing speed, a large curing strain, and poor surface transferability. There is a problem that physical properties such as refractive index, transmittance, heat resistance are limited. There is also a method of performing the active energy ray irradiation step in a vacuum or in a non-oxygen gas, but the atmosphere has to be changed for each molding shot, which is a problem with poor efficiency in continuous lens production.

Therefore, the present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a composite mold-formed product which does not impair the physical properties such as surface accuracy of the molded product and has high production efficiency, and the same. It is to provide a manufacturing method and a molding die thereof.

[0008]

In order to solve the above-mentioned problems and to achieve the object, a method for producing a composite molded article according to the present invention is such that an active energy ray-curable resin and a molded article base material are provided in a molding die. A composite molded article in which the resin layer is supplied, clamped, irradiated with an active energy ray to cure the resin, and released to form a cured resin layer on the surface of the molded article base material. In the manufacturing method of, the molding of the resin layer using a mold having a polymeric frame body whose inner peripheral shape is smaller than the outer peripheral shape of the molded product base material on the outer peripheral surface of the molding die. Is characterized by.

Further, in the method for manufacturing a composite molded product according to the present invention, the height of the frame is set to be substantially the same as the thickness of the resin layer to be closely molded on the surface of the molded product base material. It is characterized by being. Further, in the method for manufacturing a composite molded product according to the present invention, the frame body is fixed to the surface of the molding die with an adhesive.

Further, in the method of manufacturing a composite mold product according to the present invention, the frame is fitted and fixed to the main body of the mold. Further, in the method of manufacturing a composite mold product according to the present invention, the frame is integrally molded with the mold. Further, in the method for manufacturing a composite-type molded product according to the present invention, the frame body is formed of a fluorine-based or silicone-based rubber.

Further, in the method for producing a composite molded product of the present invention, an active energy ray-curable resin and a molded product base material are supplied to a molding die, and after the mold is clamped, an active energy ray is irradiated. In the method for producing a composite molded article, in which the resin is cured and released from the mold, a cured resin layer is closely formed on the surface of the molded article base material. Arranging a polymer frame smaller than the outer peripheral shape of the molded product base material, and integrally molding the molded product base material and the polymer frame body when curing the resin Is characterized by.

In the method for manufacturing a composite molded product according to the present invention, the height of the frame is set to be substantially the same as the thickness of the resin layer to be closely molded on the surface of the molded product base material. It is characterized by being. Further, in the method for manufacturing a composite-type molded product according to the present invention, the frame body is formed of a fluorine-based or silicone-based rubber.

The mold of the composite mold product of the present invention is
By supplying an active energy ray-curable resin and a molded product base material to a molding die, and after mold clamping of the molding die, the active energy ray is irradiated to cure the resin and release the molded product base material. A molding die for use in a method for producing a composite mold molded article in which a cured resin layer is closely molded on the surface of the molding die, the inner peripheral shape of which is on the outer peripheral surface of the molding die from the outer peripheral shape of the molding base material. Is characterized by having a small polymer frame.

Further, in the molding die of the composite molding product according to the present invention, the height of the frame is set to be substantially the same as the thickness of the resin layer to be closely molded on the surface of the molding base material. It is characterized by being. Further, in the molding die of the composite molding product according to the present invention, the frame body is
It is characterized in that it is fixed to the surface of the mold with an adhesive.

Further, in the molding die of the composite molding according to the present invention, the frame is fitted and fixed to the main body of the molding die. Further, the molding die of the composite molding according to the present invention is characterized in that the frame body is integrally molded with the molding die. Further, the molding die of the composite molding according to the present invention is characterized in that the frame is made of a fluorine-based or silicone-based rubber.

Further, the composite molded article of the present invention comprises:
It is manufactured by the manufacturing method described in 1. Further, the composite molded article of the present invention is manufactured by the manufacturing method according to claim 7.

[0017]

As described above, since the composite mold product, the method for producing the same, and the mold according to the present invention are configured,
Since the outer peripheral surface of the resin layer formed on the surface of the molded product base material is isolated from the outside air by the frame body, the uncured outer peripheral surface of the resin layer is prevented, and the post-process such as wiping of the uncured resin is performed. It can be omitted and the production efficiency can be improved.

Further, since it is not necessary to use a resin material which is not affected by oxygen, it is possible to prevent deterioration of physical properties due to distortion of the resin layer.

[0019]

The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. [First Embodiment] FIGS. 1 to 3 are views showing a structure of a molding die used in the first embodiment and a molding procedure.

In FIG. 1, reference numeral 1 is a base material, and in the case of an aspherical lens, it is a glass spherical lens which has been washed in advance, and a silane coupling treatment or the like for promoting adhesion on the surface to which the resin is adhered. You may give it. 3 is a molding die of this embodiment, and a polymer ring 4 is adhered and fixed to the peripheral portion of the surface of the die by an adhesive 5. The molding surface of the molding die 3 used here (upper surface in the figure) has a shape opposite (transferred) to the desired aspherical surface, and as the material of the molding die, starting from steel materials, super steel materials, nickel, copper, etc. ,Brass,
It is made of aluminum, glass, plastic, ceramics, etc., and is processed by a polishing method or a cutting method as shown in the figure.

The polymer ring 4 used here is also used.
Has an inner diameter at least smaller than the outer diameter of the glass lens of the base material 1, and has a thickness of the forming mold 3
When it is adhesively fixed to the mold, a thickness is required so as to protrude from the mold surface by the thickness of the resin to be molded from the mold surface. The material may be any polymer material, such as polyethylene, polypropylene,
Polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, nylon, polycarbonate, acrylic, polyester, polystyrene, polyacetal, polyarylate, polyetherimide, polyvinyl alcohol, polyimide, polyphenylene oxide, polysulfone,
Polyfluoroethylene, silicone resin, AS resin, AB
S resin, various liquid crystal polymers, polyurethane, epoxy resin, phenol resin, unsaturated polyester, styrene butadiene rubber, butadiene rubber, butyl rubber, urethane rubber, isoprene rubber, ethylene propylene rubber, silicone rubber, acrylic rubber, nitrile rubber, fluorine-based It is selected from rubbers, various thermoplastic elastomers, and the like, or plastics or rubbers made of a mixture thereof, but fluorine-based rubbers or silicone-based rubbers are preferable because they are flexible and have good releasability.

Examples of the fluorinated rubber include vinylidene fluoride-3 fluoroethylene chloride copolymer, vinylidene fluoride-6 fluoropropylene copolymer, vinylidene fluoride-6 fluoropropylene-4 fluoroethylene copolymer. Coalescing,
It is selected from tetrafluoroethylene-propylene copolymer, fluorinated thermoplastic elastomer, fluorinated vinyl ether and the like, and as the silicone rubber, heat vulcanizable millable silicone rubber and room temperature vulcanizable RTV silicone are used. To be elected. Further, the method for producing the polymer ring may be any method such as an injection molding method, a cast molding method and a cutting method.

As a method for connecting the polymer ring to the forming die, as shown in FIG. 1, for example, a method using an adhesive 4, such as an epoxy type, an acrylic type, a nitrile type, or a silicon type adhesive, and FIGS. As described above, a method may be employed in which a fitting projection or a jagged pattern is provided in the connection portion and the connection is performed only by the fitting force without using an adhesive. Further, as shown in FIG. 6, a cylindrical polymer ring may be fitted so as to cover the entire outer circumference of the molding die 3. Further, even in the case of these fittings, it is more preferable to use an auxiliary adhesive agent in combination so that the adhesiveness is improved and a molding die having good durability can be obtained.

In addition to the method in which the molding die and the polymer ring are separately processed and connected by bonding or fitting as described above, the molten polymer resin and the die are directly and integrally injected into the molding die. By using a method of forming outsert by molding or a similar method, or a method of cast molding with a reactive monomer and a mold or a method of outsert molding by a similar method, it is possible to connect well, so that the forming mold Durability is increased.

Next, as shown in FIG. 1, a liquid active energy ray-curable resin 2 before the reaction is supplied onto the surface of the molding die 3 or the surface of the base material 1 by a method such as a dropper or a dispenser. Like this, align the optical axes of the base material and the aspheric surface of the mold,
Also, the die is clamped by a jig tool not shown in the figure so that the outer peripheral portion of the base material contacts the upper surface of the polymer ring 4,
The active energy ray is irradiated to cure the active energy ray curable resin. At this time, there is no portion where the resin is in contact with air like the side surface 24 of the active energy ray-curable resin layer as shown in FIG. 26 of the conventional example, that is, it is sealed by the polymer ring 4 in FIG. 2 of the present embodiment. Therefore, the side surface of the active energy ray-curable resin layer is sufficiently cured. Then, the mold is released to obtain the composite type aspherical lens shown in FIG.

The active energy ray curable resin used here may be any one such as an ultraviolet curable resin, a visible ray curable resin, an X-ray curable resin, etc. Among them, the ultraviolet curable resin is easy to handle and has a wide variety of light sources. It is easy to use for the reason. Examples of the resin include acrylic-based, epoxy-based, and enthiol-based resin-based resins. Among them, acrylic-based UV-curable resins are preferable because they have a short curing time and good environmental durability.

The positional relationship between the base material 1 and the polymer ring 4 before the active energy ray-curable resin is cured is as shown in FIG. 7. Along with the curing shrinkage, the shrinkage stress acts in the direction indicated by the white arrow in FIG. 8, that is, in the direction in which the molding die and the base material approach each other. At this time, since the polymer ring 4 has its flexible property, it slightly elastically deforms due to the above-mentioned contraction stress and plays a role of absorbing the contraction stress. Therefore, the material of the polymer ring 4 used here is more preferably a rubber-like material having an appropriately low elastic modulus as described above. If the polymer ring 4 is a metal ring, the above-described shrinkage stress absorption and curing is hardly obtained, and therefore the resin strain remains at the time of curing to cause transfer failure of the surface, and the sink mark, Defects such as early peeling may occur.

Further, in the releasing step of this embodiment, when the side surface of the base material as shown in FIG. 9 is pulled upward by an L-shaped releasing jig or the like to release the mold, first, the active energy ray is used. The cured product 2 of the cured resin and the polymer ring 4 must be released from the release start portion 9 (indicated by an arrow). In this case, if the active energy ray-curable resin and the polymer ring 4 are in close contact with each other, the mold release stress increases, and the surface accuracy of the molded product deteriorates or the molded product often breaks. Therefore, it is preferable that the polymer ring 4 used here has a low adhesion to the active energy ray-curable resin. Considering the above-mentioned shrinkage stress absorption curing, the polymer ring 4 is made of fluororubber. Alternatively, it is preferable to use silicone rubber.

Although an example of an aspherical lens has been described above, the present invention is not limited to this, and it goes without saying that the present invention can be applied to optical elements such as a Fresnel lens and a diffraction grating, and other complex precision molded products. . (Specific Example 1) φ32 mm, R1 surface is R230 mm concave surface, R2
A base material (spherical concave lens) having a concave surface of R55 mm, a central thickness of 2.5 mm, and a material BK7 was prepared. Separately, the base material lens R2
The center thickness is 50 μm and the middle portion thickness is 160
An optical cutting aspherical metal mold with an outer diameter of 32 mm and an upper outer diameter of 26 mm, which has an optical aspherical surface with a diameter of μm and has a notch on the outer peripheral surface as shown in FIG. The notch has an inner diameter of 26 mm, an outer diameter of 32 mm, and a height of 5 mm, made of silicon rubber (Shin-Etsu Silicon KE-1
The ring of (603) was fitted, and a molding die was prepared by adhesive bonding as shown in FIG. 1 with a silicone adhesive so that the thickness of the ring protruding from the die surface was about 100 μm.

Next, the R2 surface side of the base lens was previously treated with a silane coupling agent (γ-acryloylpropyltrimethoxysilane), and a bifunctional urethane acrylate (M-120, Toa Gosei Co., Ltd.) was used as an ultraviolet curable resin.
0) 30% by weight, cyclohexyl methacrylate 70% by weight, 1-hydroxycyclohexyne phenyl ketone 2
55 μl of a mixture of 50% by weight was dropped onto the center of the molding die, and the R2 surface side of the base material lens was gradually brought into contact with the resin solution immediately while aligning the optical axes of the optical axis lens of the base material lens and the die. Tightened.

Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The releasability and surface transferability were good, and the peripheral portion of the resin layer of the molded product was completely cured without stickiness. (Specific example 2) A base material lens and an aspherical surface mold similar to those of specific example 1 are prepared, and a notch portion of the mold is made of a fluorine-based rubber having an inner diameter of 26 mm, an outer diameter of 32 mm and a height of 5 mm ( A mold made by fitting a ring of Viton B) manufactured by DuPont Co., Ltd., and adhesively fixing it as shown in FIG. 1 using an epoxy adhesive so that the protruding thickness of the ring from the mold surface was about 100 μm was prepared.

Next, the base material lens was pretreated in the same manner as in Example 1, and 40% by weight of a bifunctional epoxy acrylate (Kyoeisha fat and oil, 3002A) as an ultraviolet curable resin, 60% by weight of isobornyl methacrylate, and 1-hydroxy were used. 55 μl of a mixed solution of 2% by weight of cyclohexyl phenyl ketone was dropped into the center of the above-mentioned molding die, and immediately the R2 surface side of the base material lens was gradually brought into contact with the resin solution, and the optical axis of the base material lens was aligned with the mold. Tightened.

Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The releasability and surface transferability were good, and the peripheral portion of the resin layer of the molded product was completely cured without stickiness. (Specific example 3) A base material lens and an aspherical surface mold similar to those in specific example 1 are prepared, and a polyethylene ring having an inner diameter of 26 mm, an outer diameter of 32 mm and a height of 5 mm is formed in a notch of the mold. The rings were bonded and fixed by outsert molding using an injection molding machine and a mold so that the projected thickness of the ring from the surface was about 100 μm.

Next, the base material lens is pretreated in the same manner as in Embodiment 1, 55 μl of the same liquid mixture of the UV curable resin as that in Embodiment 1 is dropped into the center of the above mold, and immediately the base lens is prepared. The R2 surface side was gradually brought into contact with the resin liquid, and the mold was clamped while aligning the optical axes of the mold and the base material lens. Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The peripheral portion of the resin layer of the molded product was completely cured without stickiness, and the surface transferability was good. (Specific Example 4) A base material lens and an aspherical surface mold similar to those of Specific Example 1 are prepared, and an epoxy ring having an inner diameter of 26 mm, an outer diameter of 32 mm and a height of 5 mm is formed in a notch of the mold. Adhesion was fixed by outsert molding using a casting mold so that the thickness of the ring protruding from the surface was about 100 μm.

Next, the base material lens is pretreated in the same manner as in Embodiment 1, 55 μl of the same liquid mixture of the ultraviolet curable resin as that in Embodiment 1 is dropped into the center of the molding die, and immediately the base material lens The R2 surface side was gradually brought into contact with the resin liquid, and the mold was clamped while aligning the optical axes of the mold and the base material lens. Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The peripheral portion of the resin layer of the molded product was completely cured without stickiness, and the surface transferability was good. (Specific Example 5) A base material lens similar to that of Specific Example 1 and having a height of 30
mm, the outer diameter is 26 mm, and the upper surface has a spherical shape similar to that of Example 1, and the inner diameter is φ2.
A polyacetal resin cylindrical ring having a diameter of 6 mm, an outer diameter of 32 mm and a height of 30.1 mm was fixed by fitting so that the thickness of the ring protruding from the mold surface was about 100 μm.

Next, the base material lens is pre-treated in the same manner as in Embodiment 1, 55 μl of the same ultraviolet curable resin mixture as in Embodiment 2 is dropped into the center of the above mold, and immediately the base lens is prepared. The R2 surface side was gradually brought into contact with the resin liquid, and the mold was clamped while aligning the optical axes of the mold and the base material lens. Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The peripheral portion of the resin layer of the molded product was completely cured without stickiness, and the surface transferability was good. (Comparative Example 1) A base lens similar to that of Example 1 and having an outer diameter of φ3
We prepared an aspherical mold with a cutout of 2 mm.

Next, the base material lens is pretreated in the same manner as in Embodiment 1, 55 μl of the same ultraviolet curable resin mixture as in Embodiment 1 is dropped into the center of the molding die, and the base material lens is immediately added. While gradually contacting the R2 surface side with the resin liquid, as shown in FIG. 26, while aligning the optical axes of the mold and the base material lens,
The mold was clamped by a jig or the like (not shown) so that the thickness of the resin layer in the peripheral portion was 100 μm.

Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The mold releasability and surface transferability were good, but stickiness remained in the peripheral portion of the resin layer of the molded product and curing was incomplete. (Comparative Example 2) A base material lens and an aspherical surface mold similar to those of Example 1 are prepared, and an aluminum ring having an inner diameter of 26 mm, an outer diameter of 32 mm and a height of 5 mm is provided in the notch of the mold. The thickness of the ring protruding from the die surface when fitted is approximately 100 μm
As shown in FIG. 1, a molding die was prepared in which the epoxy adhesive was used to achieve the following.

Next, the base material lens is pretreated in the same manner as in Embodiment 1, 55 μl of the same liquid mixture of the UV curable resin as that in Embodiment 2 is dropped on the center of the above mold, and R2 of the base material lens is immediately added. The surface side was gradually brought into contact with the resin liquid, and the mold was clamped while aligning the optical axes of the mold and the base material lens. When the resin was cured by irradiating it with ultraviolet rays from a 200 W mercury-xenon lamp for 2 minutes from above, a sink defect occurred between the mold surface and the resin layer during the irradiation of ultraviolet rays, and a good molded product could not be obtained. .

As described above, according to the method for producing a composite molded article and the molding die thereof of the present embodiment, stickiness due to defective curing of the peripheral portion of the resin layer, which has been a problem in the past, is eliminated. There is no stain and the handling of the molded product is improved. Further, when the resin is cured, there is curing that absorbs curing shrinkage, so that the surface transferability of the molded product becomes good.
Further, since the peripheral portion of the resin cured product is in contact with the material having a good mold release property, the mold release can be smoothly performed. [Second Embodiment] FIGS. 10 to 15 are views showing the structure of a molding die used in the second embodiment and the molding procedure.

FIG. 10 is a perspective view of the polymer ring 11, and FIG. 11 is a sectional view of the polymer ring 11 immediately before the polymer ring 11 is installed on the outer peripheral surface of the molding die 12. The inner diameter of the polymer ring 14 used here must be at least smaller than the outer diameter of the glass lens of the base material 13, which will be described later, and the thickness of the ring 14 of the target active energy ray-curable resin layer. It is preferable that the thickness is equal to or slightly thicker than the outer peripheral portion.

Any material may be used as long as it is a polymer material, for example, polyethylene, polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, nylon, polycarbonate, acrylic, polyester, polystyrene, polyacetal, polyarylate, Polyetherelimide, polyvinyl alcohol, polyimide, polyphenylene oxide, polysulfone, polyfluoroethylene, silicone resin, AS resin, ABS resin, various liquid crystal polymers, polyurethane,
Epoxy resin, phenolic resin, unsaturated polyester,
Styrene butadiene rubber, butadiene rubber, butyl rubber, urethane rubber, isoprene rubber, ethylene propylene rubber, chloroprene rubber, silicone rubber, acrylic rubber, nitrile rubber, fluorine rubber, various thermoplastic elastomers, etc., or a plastic containing a mixture thereof. Although it is selected from the group consisting of rubbers and rubbers, those having a flexibility of polyethylene or more are preferable, and those having a degree of absorbing the curing shrinkage stress described later are preferable.

The polymer ring 11 may be manufactured by any method such as an injection molding method, a cast molding method and a cutting method. For example, a film or sheet shape is punched into a ring shape. It is preferable if it can be manufactured at low cost. The shape of the molding die 12 used here (upper surface in the figure) is the opposite (transferred) shape of the desired aspherical surface, and as the material of the molding die, there are steel materials, super steel materials, nickel, It is made of copper, brass, aluminum, glass, plastic, ceramics, etc., and it is processed by polishing or cutting as shown in the figure.

Next, as shown in FIG. 12, a polymer ring 11 is placed on the outer peripheral surface of the mold so that the center of the ring and the optical axis of the aspherical surface are aligned with each other, and then a base material 13 is prepared. Base material 13
In the case of an aspherical lens, it is a glass spherical lens that has been washed in advance, and the surface to which the resin adheres may be subjected to silane coupling treatment or the like for promoting the adhesion.

Next, a liquid active energy ray-curing resin 14 is supplied onto the surface of the mold or the surface of the base material 13 before the reaction by means of a dropper, a dispenser or the like, and the base material 13 and the gold are charged as shown in FIG. Match the optical axes of the aspherical surfaces of the mold 12,
Further, the die is clamped by a jig or the like (not shown) so that the outer peripheral portion of the base material 13 contacts the upper surface of the polymer ring 11. In some cases, pressure may be applied from above at this time.

At this time, the polymer ring 11 had a rectangular cross section until FIG. 12, but after being clamped as shown in FIG. 13, it is sandwiched between the molding die 12 and the base lens 13. Due to the flexible nature of the polymer, it conforms to the mold surface and the lens surface of the base material as if it were deformed into a spherical or aspherical shape. If the polymer ring is hard to fit, or if the target lens has a small radius of curvature and is difficult to fit, a polymer ring with a shape corresponding to the target curvature in advance as shown in FIG. 15 is used. The ring may be prepared by an injection molding method or the like and used.

Further, active energy rays are irradiated from the side of the base material 13 to cure the active energy ray curable resin. At this time, there is no portion where the resin is in contact with air like the side surface 24 of the active energy ray-curable resin layer as shown in FIG. 26 of the conventional example in FIG. 13 of the present embodiment. That is, since it is sealed by the polymer ring 11, the side surface of the active energy ray-curable resin layer is sufficiently cured. Then release the mold,
The composite type aspherical lens of the present embodiment in which the polymer ring 11 is closely formed on the side surface of the active energy ray-curable resin layer of FIG. 14 is obtained.

The active energy ray curable resin used here may be any of ultraviolet curable resin, visible ray curable resin, X-ray curable resin, etc. Among them, the ultraviolet curable resin is easy to handle and has a wide variety of light sources. Easy to use for some reason. As the resin, acrylic type, epoxy type,
A resin system such as an enthiol system can be used, and among them, an acrylic ultraviolet curing resin is preferable because it has a short curing time and good environmental durability.

Further, the positional relationship between the base material 13 and the polymer ring 11 before the active energy ray-curable resin is cured is as shown in FIG. 23. Along with the curing shrinkage, the curing shrinkage stress 16 acts in the direction indicated by the white arrow in FIG. 23, that is, in the direction in which the mold 12 and the base material 13 approach each other. At this time, since the polymer ring 11 has the soft property, it slightly deforms due to the shrinkage stress and serves to absorb the shrinkage stress. Therefore, as the material of the polymer ring 11 used here, as described above, it is more preferable that it has appropriate flexibility and rubber-like properties. If the polymer ring 11 is a metal ring, the effect of absorbing the shrinkage stress described above is hardly obtained, so that internal strain of the resin remains at the time of curing to cause defective transfer of the surface, which is accompanied. Defects such as sink marks and early peeling may occur.

Further, here, in order for the active energy ray-curable resin and the polymer ring 11 to be tightly molded, the adhesive force between the active energy ray-curable resin and the polymer is required. Generally, the active energy ray-curable resin has adhesiveness with the above-mentioned polymers, but as a better combination, for example, when the active energy ray-curable resin is an acrylic resin, an acrylic resin is used as the polymer. , Polyethylene, AS resin, ABS resin, styrene-butadiene rubber,
Acrylic rubber, urethane rubber and the like can be mentioned, and when the active energy ray curing resin is an epoxy resin, examples of the polymer include epoxy resin, polyvinyl alcohol, polyvinyl acetate, styrene butadiene rubber, acrylic rubber and urethane rubber. .

The adhesion between the polymer ring 11 and the base material glass is not shown in the figure, but a small amount of the active energy ray-curable resin permeates into the gap between the polymer ring 11 and the base material 13. Then, the polymer ring 11 and the base material 13 are bonded together. However, in order to strengthen the tight contact,
For example, when a polymer ring 11 having a shape as shown in FIG. 16 is prepared and a base material 13 is fitted into the ring 11 as shown in FIG. 17, the polymer ring is easy to handle in a post process of the molded product. 11 is preferred because there is no risk of peeling.

Further, in FIG. 12, a polymer ring 11
When the is installed in the mold 12, as means for determining the position of the polymer ring 11, as shown in FIGS.
It is preferable to make the positioning projections around the molding die for easier manufacturing process. Although the above description has been given of the example of the aspherical lens, it goes without saying that the present invention is not limited to this, and can be applied to optical elements such as a Fresnel lens and a diffraction grating, and other complex precision molded products.

As an example, the case where the present invention is applied to the production of a diffraction grating is shown in FIGS. Mold 12 of FIG.
Is a mold obtained by etching metal or glass by a photolithography technique or the like, and its outer shape is a circle or a quadrangle, although it varies depending on the intended use. Therefore, in the case of a quadrangular shape, the base glass 13 is also a square plate, and the polymer ring 11 is also a quadrangular ring.

Next, specific examples in which molded articles of various shapes are molded by the molding method of this embodiment will be described. (Specific Example 1) A base material (spherical convex lens) of material BK7 having a diameter of 25 mm, a convex surface of R1 surface of 180 mm, a convex surface of R2 surface of R45 mm, a center thickness of 3.8 mm was prepared. Separately, with respect to the R2 surface of the base material lens, the center thickness is 150 μm, and the intermediate portion thickness is 280
A cutting aspherical mold made of aluminum having an optical diameter of 25 μm and a peripheral thickness of 200 μm and an outer diameter of φ25 mm as shown in FIG.
An acrylic rubber ring with an outer diameter of 25 mm and a thickness of 0.2 mm was installed.

Next, the R2 surface side of the base material lens was previously treated with a silane coupling material (γ-acryloylpropyltrimethoxysilane), and bifunctional urethane acrylate (Toa Gosei, M-120 as an ultraviolet curable resin was used.
0) 30% by weight, cyclohexyl methacrylate 70% by weight, 1-hydroxycyclohexyl phenyl ketone 2
80 μl of a mixed solution of weight% was dropped on the central part of the molding die, and immediately the R2 surface side of the base material lens was gradually brought into contact with the resin solution, and the mold was clamped while aligning the optical axes of the base material lens and the mold. .

Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The mold releasability and surface transferability were good, and the polymer ring made of acrylic rubber was closely molded on the peripheral portion of the resin layer of the molded product, and the peripheral portion was completely cured without stickiness. (Specific example 2) The same base material lens and aspherical mold as in specific example 1 are prepared, and an acrylic cast molding having an inner diameter of 29 mm and an inner thin portion thickness of 0.2 mm as shown in FIG. The ring was placed on the mold surface.

Next, the base material lens was pretreated in the same manner as in Example 1, and 40% by weight of a bifunctional epoxy acrylate (Kyoeisha fat and oil, 3002A), 60% by weight of isobornyl methacrylate and 1-hydroxy were used as an ultraviolet curable resin. 80 μl of a mixed solution of 2% by weight of cyclohexyl phenyl ketone was dropped onto the center of the above mold, and immediately the R2 surface side of the base material lens was gradually brought into contact with the resin solution, and the optical axis of the base material lens was aligned with the mold. Tightened.

Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The mold releasability and the surface transfer property were good, and an acrylic polymer ring was closely formed on the periphery of the resin layer of the molded product, and the periphery was completely cured without stickiness. (Specific Example 3) As shown in FIG. 20, as a base material, a 20 mm square, soda lime glass having a thickness of 3 mm and outer dimensions of 20 × 20 are used.
× 1 mm, grid pitch 4 μm, convex width 2 μm, concave width 2
A diffraction grating mold made of crystalline silicon with a groove depth of 1 μm and a groove depth of 1 μm is prepared.
A square ring made of styrene-butadiene rubber having a size of 0 × 20 mm and a thickness of 0.2 mm was installed.

Next, the preform lens was pretreated in the same manner as in Example 1, 55 μl of the same ultraviolet curable resin mixture as in Example 1 was dropped into the center of the above mold, and immediately the preform glass was prepared. The treated surface side was gradually brought into contact with the resin liquid, and the mold was clamped while aligning the outer periphery of the mold and the base material glass. Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. A styrene-butadiene rubber ring was adhered to the peripheral part of the resin layer of the molded product as shown in FIG. 22, and the peripheral part was completely cured without stickiness. (Comparative Example 1) A base material lens and an aspherical mold similar to those of Example 1 were prepared.

Next, the base material lens is pretreated in the same manner as in Embodiment 1, 80 μl of the same mixture liquid of the UV curable resin as in Embodiment 1 is dropped into the center of the above molding die, and immediately the base lens is prepared. While gradually contacting the R2 surface side with the resin liquid, as shown in FIG. 26, while aligning the optical axes of the mold and the base material lens,
The mold was clamped by a jig or the like (not shown) so that the thickness of the peripheral resin layer was 200 μm.

Ultraviolet rays from a 200 W mercury-xenon lamp were irradiated from above for 2 minutes to cure the resin, and then the mold was released. The mold releasability and surface transferability were good, but stickiness remained in the peripheral portion of the resin layer of the molded product, and curing was incomplete. (Comparative Example 2) A base glass and a diffraction grating mold similar to those of Example 3 were prepared, and the surface thereof had a square shape made of aluminum having an inner dimension of 16 x 16 mm, an outer dimension of 20 x 20 mm and a thickness of 0.2 mm. The ring was installed.

Next, the preform glass was pretreated in the same manner as in Example 1, 55 μl of the same liquid mixture of the ultraviolet curable resin as in Example 1 was dropped into the center of the above mold, and the preform glass was immediately treated. The surface side was gradually brought into contact with the resin liquid, and the mold was clamped while aligning the outer periphery of the mold and the base glass. When the resin was cured by irradiating it with ultraviolet rays from a 200 W mercury-xenon lamp for 2 minutes from above, a sink defect occurred between the mold surface and the resin layer during the irradiation of ultraviolet rays, and a good molded product could not be obtained. .

As described above, according to the composite molded article and the method of manufacturing the same of the present embodiment, stickiness due to insufficient curing of the peripheral portion of the resin layer, which has been a problem in the past, is eliminated, and thus stains due to the uncured resin are eliminated. The handling of the molded product is improved. Further, when the resin is cured, it has an effect of absorbing curing shrinkage, so that the surface transferability of the molded product becomes good. It should be noted that the present invention can be applied to a system composed of a plurality of devices as well.
It may be applied to an apparatus composed of one device. Further, it goes without saying that the present invention can be applied to the case where it is achieved by supplying a program to a system or an apparatus.

Further, the present invention can be applied to the modified or modified embodiment described above without departing from the spirit of the invention.

[0065]

As described above, according to the composite molded article, the method for producing the same and the molding die of the present invention, the outer peripheral surface of the resin layer formed on the surface of the base material of the molded article is protected from outside air by the frame. Since it is isolated, the uncured outer peripheral surface of the resin layer is prevented, and the post-process such as wiping of the uncured resin is omitted, and the production efficiency can be improved.

Further, since it is not necessary to use a resin material which is not affected by oxygen, it is possible to prevent deterioration of physical properties due to distortion of the resin layer.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a manufacturing method and a forming die of a first embodiment according to the present invention.

FIG. 2 is a cross-sectional view showing a manufacturing method and a forming die according to the first embodiment of the present invention.

FIG. 3 is a cross-sectional view showing a manufacturing method and a forming die according to the first embodiment of the present invention.

FIG. 4 is a cross-sectional view showing another example of the molding die according to the first embodiment.

FIG. 5 is a cross-sectional view showing another example of the molding die according to the first embodiment.

FIG. 6 is a cross-sectional view showing another example of the molding die according to the first embodiment.

FIG. 7 is a detailed view showing the manufacturing method of the first embodiment.

FIG. 8 is a detailed view showing the manufacturing method of the first embodiment.

FIG. 9 is a detailed view showing the manufacturing method of the first embodiment.

FIG. 10 is a perspective view of an example of a polymer ring used in the second embodiment according to the present invention.

FIG. 11 is a cross-sectional view showing the manufacturing method of the second embodiment.

FIG. 12 is a cross-sectional view showing the manufacturing method of the second embodiment.

FIG. 13 is a cross-sectional view showing the manufacturing method of the second example.

FIG. 14 is a cross-sectional view showing a composite molded product of a second embodiment.

FIG. 15 is a cross-sectional view showing another example of the polymer ring used in the second embodiment.

FIG. 16 is a cross-sectional view showing another example of the polymer ring used in the second embodiment.

FIG. 17 is a sectional view showing another example of the composite-type molded product of the second embodiment.

FIG. 18 is a cross-sectional view showing another example of the mold used in the manufacturing method of the second embodiment.

FIG. 19 is a cross-sectional view showing another example of the mold used in the manufacturing method of the second embodiment.

FIG. 20 is a cross-sectional view showing another example of the manufacturing method of the second embodiment.

FIG. 21 is a cross-sectional view showing another example of the manufacturing method of the second embodiment.

FIG. 22 is a cross-sectional view showing another example of the manufacturing method of the second embodiment.

FIG. 23 is a cross-sectional view showing details of the manufacturing method of the second example.

FIG. 24 is a cross-sectional view showing details of the manufacturing method of the second example.

FIG. 25 is a cross-sectional view showing a conventional example.

FIG. 26 is a cross-sectional view showing a conventional example.

FIG. 27 is a cross-sectional view showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Active energy ray hardening resin 3 Mold 4 Polymer ring 5 Adhesive 6 Fitting part 7 Elastic deformation of polymer ring 8 Release jig 9 Release start part 11 Polymer ring 12 Mold 13 Base material 14 Active energy ray curable resin 15 Mold projection 16 Curing shrinkage stress 17 Polymer ring deformation 21 Base material 22 Active energy ray curable resin 23 Mold 24 Resin layer side surface

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Claims (17)

[Claims] 1. An active energy ray-curable resin and a molded article base material are supplied to a molding die, and after the molding die is clamped, an active energy ray is irradiated to cure the resin and release the mold. In the method for producing a composite mold molded article in which a cured resin layer is closely molded on the surface of the molded product base material, the inner peripheral shape of the surface outer peripheral portion of the molding die is smaller than the outer peripheral shape of the molded product base material. A method for producing a composite molded article, which comprises molding the resin layer using a mold provided with a molecular frame. 2. The height of the frame is set to be substantially the same as the thickness of the resin layer to be closely molded on the surface of the molded product base material. A method for producing a composite molded article. 3. The method for manufacturing a composite molded product according to claim 1, wherein the frame is fixed to the surface of the mold with an adhesive. 4. The method for manufacturing a composite mold product according to claim 1, wherein the frame is fitted and fixed to the main body of the mold. 5. The method for manufacturing a composite mold product according to claim 1, wherein the frame is integrally molded with the mold. 6. The frame body is formed of fluorine-based or silicone-based rubber.
A method for producing the composite molded article according to. 7. An active energy ray-curable resin and a molded product base material are supplied to a molding die, and after the molding die is clamped, the resin is irradiated with an active energy ray to cure the resin and released. In the method for producing a composite mold molded article in which a cured resin layer is closely molded on the surface of the molded product base material, the inner peripheral shape is smaller than the outer peripheral shape of the molded product base material on the outer peripheral surface of the molding die. Place a polymer frame,
A method for producing a composite-type molded product, comprising integrally molding the molded product base material and the polymer frame body when curing the resin. 8. The height of the frame body is set to be substantially the same as the thickness of the resin layer to be closely molded on the surface of the molded product base material. A method for producing a composite molded article. 9. The frame body is formed of a fluorine-based or silicone-based rubber.
A method for producing the composite molded article according to. 10. An active energy ray-curable resin and a molded product base material are supplied to a mold, and after the mold is clamped, the resin is irradiated with an active energy ray to cure the resin and released. A molding die used in a method for producing a composite molded article in which a cured resin layer is closely molded on the surface of the molded article base material, the inner peripheral shape of which is the outer peripheral surface of the molding die. A molding die for a composite molding, comprising a polymer frame smaller than the outer peripheral shape of the material. 11. The height of the frame body is set to be substantially the same as the thickness of the resin layer to be closely molded on the surface of the molded product base material. Mold for composite molding of. 12. The mold for a composite molded product according to claim 10, wherein the frame is fixed to the surface of the mold with an adhesive. 13. The mold for a composite molded product according to claim 10, wherein the frame is fitted and fixed to the main body of the mold. 14. The mold of a composite molded product according to claim 10, wherein the frame is integrally molded with the mold. 15. The molding die for a composite molded article according to claim 10, wherein the frame body is formed of fluorine-based or silicone-based rubber. 16. A composite molded product manufactured by the manufacturing method according to claim 1. 17. A composite molded article manufactured by the manufacturing method according to claim 7.