KR20150123743A - Method for manufacturing liquid lens array mold - Google Patents

Method for manufacturing liquid lens array mold Download PDF

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Publication number
KR20150123743A
KR20150123743A KR1020150058877A KR20150058877A KR20150123743A KR 20150123743 A KR20150123743 A KR 20150123743A KR 1020150058877 A KR1020150058877 A KR 1020150058877A KR 20150058877 A KR20150058877 A KR 20150058877A KR 20150123743 A KR20150123743 A KR 20150123743A
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KR
South Korea
Prior art keywords
mold
sheet
manufacturing
slice
curing agent
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KR1020150058877A
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Korean (ko)
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KR101683699B1 (en
Inventor
원용협
정병주
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한국과학기술원
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Publication of KR20150123743A publication Critical patent/KR20150123743A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3842—Manufacturing moulds, e.g. shaping the mould surface by machining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/0048—Moulds for lenses

Abstract

Disclosed is a production method for a mold for producing a liquid lens array, which comprises the following steps: arranging at least one shaped rod of which a longitudinal section thereof has a shape of a longitudinal section of lens, and then hardening and filling an empty space within the shaped rod with a hardener to harden the same to produce a parent mold material; cutting the parent mold material in a thickness of a partition of a chamber comprising the liquid lens array to produce a mold fragment; producing a sealing layer on a longitudinal section of the mold fragment by using a mold sheet; and producing a roll to roll mold by removing the hardener from the mold fragment where the sealing layer is produced on.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method for manufacturing a liquid lens array,

The present invention relates to a method of manufacturing a mold for manufacturing a liquid lens array.

There are a variety of ways to manufacture panels with an array of chambers (hollow cylinders, holes) that make up an electro-wetted liquid lens array.

In the case of an electro-wetted liquid lens, the precision and roughness factor of the vertical wall of the chamber greatly affects the quality of the lens. When the height of the partition wall of the chamber is 100um or less, it can be manufactured precisely by an optical lithography method. However, it is disadvantageous in that the manufacturing cost is high due to the complexity of the manufacturing process and it is not suitable for mass production.

When the opening size of the chamber is 5 mm or more, it is possible to manufacture chambers by precision machining such as laser drilling, but it has a limitation in reducing the thickness of the partition wall separating the chamber and the chamber, so that the fill factor I have a falling problem.

On the other hand, a method of taking out a panel by using a mold for mass production of a low cost chamber array panel is being studied. LIGA (LIthographie Galvanoform Abformtechnik) process using the above-mentioned precision machining and lithography method is used for the production of a mold, but it has a disadvantage that it is difficult to manufacture a mold for a chamber having a bulkhead height of 100um or more in the LIGA process.

Further, in the case of precision machining, the thickness of the partition wall separating the chamber opening and the opening is limited, and the roughness of the chamber vertical wall surface can not be precisely controlled.

SUMMARY OF THE INVENTION The present invention provides a method for manufacturing a liquid lens array manufacturing mold capable of mass-producing a liquid lens array of an electrowetting type by a simple method.

According to an aspect of the present invention, there is provided a method of manufacturing a mold for manufacturing a liquid lens array,

Aligning at least one mold rod having a longitudinal cross-sectional profile of the lens longitudinal cross-section, filling the cavity between the mold rods with a curing agent to form a mold base material; Cutting the mold base material by a thickness of the partition wall of the chamber constituting the liquid lens array to produce a mold slice; Creating a sealing layer with a mold sheet on one longitudinal side of the mold slice; And removing the curing agent from the mold slice in which the sealing layer is formed to produce a roll-to-roll mold.

According to another aspect of the present invention, there is provided a method of manufacturing a mold for manufacturing a liquid lens array,

Aligning at least one mold rod having a longitudinal cross-sectional profile of the lens longitudinal cross-section, filling the cavity between the mold rods with a curing agent to form a mold base material; Cutting the mold base material by a thickness of the partition wall of the chamber constituting the liquid lens array to produce a mold slice; Forming a sealing layer with a mold sheet on a surface other than a longitudinal section of the mold section; And removing the curing agent from the mold slice in which the sealing layer is formed to produce a stamp mold.

According to another aspect of the present invention, there is provided a method of manufacturing a mold for manufacturing a liquid lens array,

Aligning at least one mold rod having a longitudinal cross-sectional profile of the lens longitudinal cross-section, filling the cavity between the mold rods with a curing agent to form a mold base material; Cutting the mold base material by a thickness of the partition wall of the chamber constituting the liquid lens array to produce a mold slice; Creating a sealing layer with a mold sheet on one longitudinal side of the mold slice; Removing the mold rod from the mold slice in which the sealing layer is formed to produce an intermediate mold; And filling the intermediate mold with PDMS (Poly Dimethylsiloxane), curing the intermediate mold, and then removing the intermediate mold to produce a flexible mold.

The method may further include grinding both longitudinal sides of the mold slice between the step of producing the mold slice and the step of producing the sealing layer.

In addition, the step of forming the mold base material may include: aligning the mold rod on a jig sheet; Attaching the mold rod to the jig sheet using the curing agent to produce a shape sheet; And forming the mold base material by laminating one or more of the shape sheets.

Further, one or more U-shaped grooves are formed on one side of the jig sheet, and the shape bar is aligned on the groove and attached to the jig sheet.

The curing agent is the same as the material of the jig sheet, and is dissolved in the solvent other than the shape bar.

Further, the shape bar is a metal, and the curing agent and the zigzate are UV oligomers.

In addition, the mold sheet is a mold sheet made of a material having high adhesiveness to the shape bar.

Further, in the step of forming the mold base material by laminating one or more of the shape sheets, the shape sheet is adhered using an adhesive in the middle of lamination of the shape sheet, and the adhesive is made of a material which melts in the solvent for melting the curing agent do.

In addition, the step of forming the mold base material may include aligning the at least one mold rod into a space; And filling the void space between the mold halves with the curing agent to cure the mold to produce the mold base agent.

According to the present invention, a liquid lens array of an electrowetting type can be mass-produced by a simple method, thereby enabling applications such as a 3D display and a light field camera to be activated.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a mold reed bar used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention; FIG.
2 is a view showing a shape in which a shape bar is coupled to a jig sheet used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention.
FIG. 3 is a view showing a shape sheet generated using the jig sheet shown in FIG. 2. FIG.
4 is a view showing a mold base material used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention.
5 is a view illustrating a process of generating a mold slice used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention.
FIG. 6 is a view illustrating a process of manufacturing a roll-to-roll mold for manufacturing a liquid lens array according to an embodiment of the present invention using the mold slice shown in FIG.
7 is a view illustrating a process of manufacturing a stamp mold for manufacturing a liquid lens array according to an embodiment of the present invention using the mold slice shown in FIG.
FIG. 8 is a view showing a process of manufacturing a flexible mold for manufacturing a liquid lens array according to an embodiment of the present invention using the mold slice shown in FIG.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily carry out the present invention. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In order to clearly illustrate the present invention, parts not related to the description are omitted, and similar parts are denoted by like reference characters throughout the specification.

Throughout the specification, when an element is referred to as "comprising ", it means that it can include other elements as well, without excluding other elements unless specifically stated otherwise. Also, the terms " part, "" module," and " module ", etc. in the specification mean a unit for processing at least one function or operation and may be implemented by hardware or software or a combination of hardware and software have.

Hereinafter, a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention will be described with reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a mold reed bar used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention; FIG.

Referring to FIG. 1, a liquid lens utilizing electric wetting phenomenon has a chamber for filling two or more kinds of solutions. Wherein the chamber is separated from the exterior by a bulkhead in a vertically hollow hollow cavity.

To take a chamber using a mold, a projection for the chamber is required in the mold, and the projection has a relief shape of the chamber. When the protrusion is elongated in the longitudinal direction, the mold rod 100 is formed.

The mold reed bar 100 may have a coating layer 110 for improving the quality of the material by smoothly machining the outer surface smoothly.

The cross section of the mold rod 100 is not limited to a circular shape as shown in FIG. 1, but may have various shapes such as a hexagon and a square.

FIG. 2 is a view showing a state where a shape bar is coupled to a jig sheet used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention. FIG. 3 is a view Fig.

2 and 3, a jig sheet 210 having a plurality of U-shaped grooves 211 formed on one side thereof at regular intervals is prepared. These grooves 211 are formed to conveniently align the mold rod 100 with the jig sheet 210. [ The shape of the groove 211 may be a triangle or the like in addition to the U shape.

Thereafter, the mold bar 100 is aligned in the U-shaped groove of the groove 211 of the jig sheet 210, and then the space created between the mold halves 100 is filled with the first curing agent 220 , And the first curing agent 220 is cured using UV (Ultra Violet) or heat to produce the shape sheet 200. At this time, a mold can be used on the outside so that the first curing agent 220 does not flow out to the outside. Further, it is preferable to use a degassing device to remove bubbles in the first curing agent 220.

The first curing agent 220 may be the same as the material of the jig sheet 210 and may be made of a material dissolving in a solvent different from that of the mold rod 100. For example, the mold 100 may melt in the first solvent and the first curing agent 220 and the jig sheet 210 may not dissolve. In addition, the first curing agent 220 and the jig sheet 210 melt in the second solvent, and the mold rod 100 should not melt. Here, the mold rod 100 is a metal, and the first curing agent 220 and the jig sheet 210 may be UV-cured by UV.

4 is a view showing a mold base material used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention.

Referring to FIG. 4, a plurality of shape sheets 200 produced in FIG. 3 are vertically stacked to produce a mold base material 300. At this time, it is preferable that the gaps of the shape sheets 200 are adhered to each other by using an adhesive. The adhesive is preferably made of a material that melts in a second solvent that melts the first curing agent 220.

The spacing between the mold halves 100 in the mold base material 300 is determined by the distance between the grooves 211 of the jig sheet 210 and the height of the jig sheet 210 constituting the shape sheet 200. That is, the arrangement interval of the mold halves 100 is determined by the design of the jig sheet 210.

Although the shape sheet 200 is used as an intermediate step in FIGS. 2 and 3 for the convenience of the mold base material 300 in the above description, the shape sheet 200 may be used as an intermediate step, The mold base material 300 may be immediately prepared by aligning the mold reed rod 100 in a space, filling a void space between the mold reed bars 100 with a hardener, and then curing using UV or heat.

5 is a view illustrating a process of generating a mold slice used in a method of manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention.

Referring to FIG. 5, the finished mold base material 300 is cut in a direction perpendicular to the length of the partition wall of the liquid lens to produce the mold slice 400 as shown in FIG. At this time, a wire saw or a laser device can be used as the cutting device 310 for cutting the mold base material 300.

Hereinafter, three methods for manufacturing a mold for manufacturing a liquid lens array according to an embodiment of the present invention will be described using a mold slice 400 produced through FIG.

First, a method of manufacturing a roll-to-roll mold will be described with reference to FIG. 6 as a first method.

FIG. 6 is a view illustrating a process of manufacturing a roll-to-roll mold for manufacturing a liquid lens array according to an embodiment of the present invention using the mold slice shown in FIG.

Referring to FIG. 6, each of the cut sides of the mold slice 400 is precisely polished using CMP (Chemical Mechanical Polishing) or the like.

Thereafter, the mold sheet 410 is attached to one surface of the mold section 400. The mold sheet piece 415 is made of a metal such as nickel or copper for the metal mold and the mold sheet 410 is adhered to the metal mold rod piece 415 to form a sealing layer.

Since the mold for the roll-to-roll process must be configured to be wound on the roll, the mold sheet 410 is made of a flexible material. In this case, the material of the mold sheet 410 may be made of a thin stainless steel.

Next, after the mold section 400 and the mold sheet 410 are combined, the jig sheet 210, the first curing agent 220, and the adhesive are removed with a second solvent to finally produce a roll-to-roll mold 500 .

The manufactured roll-to-roll mold 500 has a structure in which the mold-shaped bar 415 is arranged on the mold sheet 410. By using the roll-to-roll mold 500, a chamber array for a liquid lens array can be produced by a roll-to-roll process.

Next, a method of manufacturing a stamped mold will be described with reference to FIG. 7 as a second method.

7 is a view illustrating a process of manufacturing a stamp mold for manufacturing a liquid lens array according to an embodiment of the present invention using the mold slice shown in FIG.

Referring to FIG. 7, each of the cut sides of the mold slice 400 is precisely polished using CMP or the like.

Thereafter, the mold sheet 420, which can cover all surfaces except for only one side of the mold section 400, is bonded to the mold section 400. Here, if the mold intercept slice 415 is made of metal such as nickel or copper, a metal layer can be formed on all sides of the mold section 400 except for one side.

Subsequently, after the mold sheet 420 is formed on the mold section 400, the jig sheet 210, the first curing agent 220 and the adhesive are removed with a second solvent to finally produce the stamp mold 510 .

An outer frame 421 is formed in the manufactured stamp mold 510 so as not to flow down when the solution for forming the chamber array is filled. By using the stamp mold 510, a chamber array for a liquid lens array can be produced by a stamping process.

Finally, as a third method, a method of manufacturing a flexible mold will be described with reference to FIG.

FIG. 8 is a view showing a process of manufacturing a flexible mold for manufacturing a liquid lens array according to an embodiment of the present invention using the mold slice shown in FIG.

Prior to explanation, flexible polymer molds have the advantage that they can be easily removed from the mold. Use an intermediate mold to create a flexible and flexible polymer mold.

Referring to FIG. 8, each of the cut sides of the mold slice 400 is precisely polished using CMP or the like.

Thereafter, the mold sheet 430 is attached to one surface of the mold section 400. The mold sheet 430 is made of a material having high adherence to the jig sheet 210, the first curing agent 220 and the adhesive and attached to one surface of the mold section 400 to form a sealing layer.

Then the mold sheet piece 415 is melted well and the mold sheet 430, the jig sheet 210, the first curing agent 220 and the adhesive melt the mold piece 415 into the first solvent which does not melt Thereby forming an intermediate mold 520.

Next, PDMS (Poly Dimethylsiloxane) is filled in the intermediate mold 520 and cured, and then the intermediate mold 520 is removed to finally form the flexible mold 530. By using the flexible mold 530 thus produced, the chamber array for a liquid lens array can be produced by the stamping process.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, It belongs to the scope of right.

Claims (12)

A method of manufacturing a mold for manufacturing a liquid lens array,
Aligning at least one mold rod having a longitudinal cross-sectional profile of the lens longitudinal cross-section, filling the cavity between the mold rods with a curing agent to form a mold base material;
Cutting the mold base material by a thickness of the partition wall of the chamber constituting the liquid lens array to produce a mold slice;
Creating a sealing layer with a mold sheet on one longitudinal side of the mold slice; And
Removing the curing agent from the mold slice in which the sealing layer is formed to produce a roll-to-roll mold
Wherein the mold is made of a plastic material. A method of manufacturing a mold for manufacturing a liquid lens array,
Aligning at least one mold rod having a longitudinal cross-sectional profile of the lens longitudinal cross-section, filling the cavity between the mold rods with a curing agent to form a mold base material;
Cutting the mold base material by a thickness of the partition wall of the chamber constituting the liquid lens array to produce a mold slice;
Forming a sealing layer with a mold sheet on a surface other than a longitudinal section of the mold section; And
Removing the curing agent from the mold slice in which the sealing layer is formed to produce a stamp mold
Wherein the mold is made of a plastic material. A method of manufacturing a mold for manufacturing a liquid lens array,
Aligning at least one mold rod having a longitudinal cross-sectional profile of the lens longitudinal cross-section, filling the cavity between the mold rods with a curing agent to form a mold base material;
Cutting the mold base material by a thickness of the partition wall of the chamber constituting the liquid lens array to produce a mold slice;
Creating a sealing layer with a mold sheet on one longitudinal side of the mold slice;
Removing the mold rod from the mold slice in which the sealing layer is formed to produce an intermediate mold; And
Filling the intermediate mold with a mold material, curing the intermediate mold, and removing the intermediate mold to produce a flexible mold
Wherein the mold is made of a plastic material. 4. The method according to any one of claims 1 to 3,
Between the step of producing the mold slice and the step of producing the sealing layer,
Further comprising the step of grinding both vertical cross-sections of the mold slice. 4. The method according to any one of claims 1 to 3,
Wherein the step of forming the mold base material comprises:
Aligning the mold rod on a jig sheet;
Attaching the mold rod to the jig sheet using the curing agent to produce a shape sheet;
Forming the mold base material by laminating one or more of the shape sheets
Wherein the mold is made of a plastic material. 6. The method of claim 5,
Wherein at least one U-shaped groove is formed on one side of the jig sheet, and the shape bar is aligned on the groove and attached to the jig sheet. 6. The method of claim 5,
Wherein the curing agent is the same as the material of the jig sheet and melts in the solvent different from the shape bar. 8. The method of claim 7,
Wherein the shape bar is a metal and the curing agent and the zigzate are UV oligomers. 4. The method according to any one of claims 1 to 3,
Wherein the mold sheet is a mold sheet made of a material having high adhesiveness to the shape rod. 6. The method of claim 5,
Characterized in that at least one of the shape sheets is laminated to form the mold base material, the shape sheet is adhered with an adhesive in the middle of lamination of the shape sheet, and the adhesive is made of a material which melts in a solvent for melting the curing agent A method for manufacturing a mold for manufacturing a lens array. 4. The method according to any one of claims 1 to 3,
Wherein the step of forming the mold base material comprises:
Aligning the at least one shaped rod in space; And
Filling the void space between the mold halves with the curing agent to cure the mold to produce the mold base agent
Wherein the mold is made of a plastic material. The method of claim 3,
Wherein the mold material to be filled in the intermediate mold in the step of forming the flexible mold is PDMS (Poly Dimethylsiloxane).
KR1020150058877A 2014-04-25 2015-04-27 Method for manufacturing liquid lens array mold KR101683699B1 (en)

Applications Claiming Priority (2)

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KR1020140049861 2014-04-25
KR20140049861 2014-04-25

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KR101683699B1 KR101683699B1 (en) 2016-12-20

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2000218655A (en) * 1999-02-03 2000-08-08 Sumitomo Electric Ind Ltd Manufacture of mold for forming microlens array
JP2002144348A (en) * 2000-10-31 2002-05-21 Eastman Kodak Co Method for manufacturing precision mold
JP2002205310A (en) * 2000-10-31 2002-07-23 Eastman Kodak Co Method of manufacturing mold for micro-lens array
JP2006159716A (en) * 2004-12-09 2006-06-22 Nikon Corp Method for producing mold for optical element

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2000218655A (en) * 1999-02-03 2000-08-08 Sumitomo Electric Ind Ltd Manufacture of mold for forming microlens array
JP2002144348A (en) * 2000-10-31 2002-05-21 Eastman Kodak Co Method for manufacturing precision mold
JP2002205310A (en) * 2000-10-31 2002-07-23 Eastman Kodak Co Method of manufacturing mold for micro-lens array
JP2006159716A (en) * 2004-12-09 2006-06-22 Nikon Corp Method for producing mold for optical element

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