201018567 九、發明說明： 【發明所屬之技術領域】 ' 本發明涉及一種射出成型模具及採用其射出成型鏡片 • 陣列之方法。 【先前技術】 光學鏡片通常採用射出成型方式實現，但是，普通射 出成型每次只能同時成型8個鏡片或16個鏡片，隨著對鏡 ©片尺寸與生產效率之要求之不斷提高，普通射出成型不能 滿足實際之需求。因而，包括複數鏡片之鏡片陣列應運而 生。先前技術中，具有晶元尺寸之光學鏡片陣列係於透光 基板兩側以壓印成型光學部（請參見The Novel Fabrication Method and Optimum Tooling Design Used for Microlens Arrays » Proceedings of the 1st IEEE International Conference on Nano/Micro Engineered and Molecular Systems ； January 18-21，2006, Zhuhai，China)之方式生產。壓印成型係指先 將液態或塑性變形之鏡片材料塗敷於透明基板上，再以壓 印模具將鏡片材料壓印形成鏡片之方式。壓印成型一次可 生產具有上千個鏡片之鏡片陣列，具有較高之生產效率。 於壓印成型之過程中，由於生產產品之精密度之要 求，需要使用奈米模壓機台，此種奈米模壓機台價格昂貴， 增加了光學鏡片之製作成本。 【發明内容】 201018567 2於此’有必要提供—種射出成型模具製造鏡片陣 列之方法，以降低鏡片生產之成本。 . 種射出成型模具’用於形成具有複數鏡片之鏡片陣 列，該射出成型模具包括第一模仁與第二模仁，該第一模 仁具有第-成型面’於第一成型面上形成有複數第一成型 部，每個第-成型部均與一個鏡片相對應，該第二模仁具 有第二成型面’該第一成型面與第二成型面相對。 -種鏡片陣列之射出成型方法，包括步驟：將上述之 射出成型模具安裝於射出成型機台；使該射出成型模具合 模以使第模仁與第一模仁形成與待成型之鏡片陣列相 對應之成型腔；使鏡片材料以大於1000毫米/秒之注射速度 射入成型腔中；固化鏡片材料，以成型鏡片陣列。 a 本技術方案之射出成型模具與鏡片陣列之射出成型方 法具有如下優點：首先，一次射出成型即可製造包括數以 千計之光學鏡片之鏡片陣列，可大大提升鏡片製作之速度 ❹與效率。其次’相較於壓印製程具有較低之生產成本。 【實施方式】 下面將結合附圖’對本技術方案實施例提供之射出成 型模具及採用其製造鏡片陣列之方法進一步之詳細說明。 請參閱圖1，本技術方案實施例提供之一種鏡片陣列射 出成型模具100，用於成型包括複數鏡片之鏡片陣列。射出 成型模具100包括相對設置之第一模仁110與第二模仁 120。 7 201018567 二-一併參閱圖2及圖3’第-模仁⑽具有第-成型面 ，第一成型® m之形狀與大小與待成型之鏡片陣列中 鏡片之個數與尺寸有關。本實施例中，第-成型面m呈 2:臺：一成型面m長度略大於谓毫米，寬度略大於 2 第一成^出上形成有複數第-成型部 第一 一成型部112於第一成型面111上陣列排布。 參 之形狀與待成型之鏡片之形狀相對應。本 兔白=’、以成型雙凸透鏡為例’每個第一成型部112均 :-成型面m向第一模仁11〇内開設之凹陷，第一 2 112之表面為球形或非球形曲面，第一成型部山 二d成型面U1上之開口為圓形，第一成型部112於第 111之開口大小與第一成型部112之曲面曲率應 出之直成^鏡片陣列中鏡片之光學要求。每個第-成型ΐ 讲斗士 单鏡片，相鄰兩個第一成型部112之間需要 毫米至置’故相鄰兩個第一成型部112之間距應為2 約：2喜Ϊ本實施例中，每個第一成型部112之直徑d 約每相鄰之兩個第一成型部112之中心之間距。 部:12。入’於第一成型面m共形成有6175個第-成型 為其：:狀成同形狀之鏡片時’第一成型’m亦可 第-成型雙凹透鏡時，第一成型部112可為白 成支面111向遠離第一模仁110凸起。 請—併參閱圖4及圖5,本實施例中，第二模仁12〇 8 201018567 121，模仁120具有第二成型面 第:成型面121之形狀與大小與第—模仁面n"目 纽：成型面121亦呈矩形，第二成型®⑵長度 =…〇毫米，寬度亦略大於26〇毫米。於第二成型 ==成有複數第二成型部122。複數第二成型部122 m1上陣列排布。每個第二成型冑122均為 =第:成型面m向第二模仁12G内開設之非球形曲面凹201018567 IX. INSTRUCTIONS: [Technical Field of the Invention] The present invention relates to an injection molding die and a method of using the same for injection molding a lens. [Prior Art] Optical lenses are usually produced by injection molding. However, ordinary injection molding can only form 8 lenses or 16 lenses at a time. With the increasing requirements for the size and productivity of the mirror, the common injection Molding does not meet the actual needs. Thus, a lens array comprising a plurality of lenses has emerged. In the prior art, an optical lens array having a wafer size is embossed on both sides of the light-transmissive substrate to form an optical portion (see The Novel Fabrication Method and Optimum Tooling Design Used for Microlens Arrays) Proceedings of the 1st IEEE International Conference on Nano /Micro Engineered and Molecular Systems ; January 18-21, 2006, Zhuhai, China). Embossing refers to the manner in which a liquid or plastically deformed lens material is applied to a transparent substrate, and then the lens material is embossed to form a lens by a stamping die. Embossing once produces an array of lenses with thousands of lenses for high productivity. In the process of imprinting, due to the precision of the production products, it is necessary to use a nano-molding machine. Such a nano-molding machine is expensive, and the manufacturing cost of the optical lens is increased. SUMMARY OF THE INVENTION 201018567 2 Here, it is necessary to provide a method for producing a lens array by injection molding to reduce the cost of lens production. An injection molding die for forming a lens array having a plurality of lenses, the injection molding die comprising a first mold core and a second mold core, the first mold core having a first molding surface formed on the first molding surface A plurality of first molding portions, each of the first molding portions corresponding to one lens, the second mold core having a second molding surface 'the first molding surface opposite to the second molding surface. - an injection molding method for a lens array, comprising the steps of: mounting the above-mentioned injection molding die on an injection molding machine; and clamping the injection molding die so that the first mold core and the first mold core form a lens array to be formed Corresponding molding cavity; the lens material is injected into the molding cavity at an injection speed of more than 1000 mm/sec; the lens material is cured to form a lens array. a The injection molding method of the injection molding die and the lens array of the present technical solution has the following advantages: First, a lens array including thousands of optical lenses can be manufactured by one injection molding, which can greatly improve the speed and efficiency of lens manufacturing. Secondly, there is a lower production cost compared to the imprint process. [Embodiment] Hereinafter, an injection molding die provided by an embodiment of the present technical solution and a method for manufacturing the lens array thereof will be further described in detail with reference to the accompanying drawings. Referring to FIG. 1, a lens array injection molding die 100 according to an embodiment of the present invention is provided for molding a lens array including a plurality of lenses. The injection molding die 100 includes a first die 110 and a second die 120 that are disposed opposite each other. 7 201018567 II-II Referring to Fig. 2 and Fig. 3', the first mold core (10) has a first forming surface, and the shape and size of the first forming product m are related to the number and size of the lenses in the lens array to be formed. In this embodiment, the first forming surface m is 2: a table: a molding surface m has a length slightly larger than a millimeter, and a width is slightly larger than 2. The first forming portion has a plurality of first forming portions and a first molding portion 112 formed thereon. A molding surface 111 is arranged in an array. The shape of the reference corresponds to the shape of the lens to be formed. The rabbit white=', taking the formed lenticular lens as an example, 'each of the first molding portions 112:- the depression of the molding surface m into the first mold core 11〇, the surface of the first 2 112 is a spherical or aspherical surface The opening of the first molding portion of the second forming surface U1 is circular, and the opening of the first molding portion 112 at the opening 111 and the curvature of the curved surface of the first molding portion 112 are straightforward. Claim. Each of the first-formed cymbal single-lens lenses requires millimeters to be placed between two adjacent first molding portions 112. Therefore, the distance between two adjacent first molding portions 112 should be about 2: 2 Magpie This embodiment The diameter d of each of the first molding portions 112 is approximately the distance between the centers of the adjacent two first molding portions 112. Department: 12. When the first molding surface m is formed with a total of 6175-first moldings: when the lens is formed into the same shape, the first molding portion may be white, and the first molding portion 112 may be white. The support surface 111 is convex away from the first mold core 110. Please refer to FIG. 4 and FIG. 5, in this embodiment, the second mold core 12〇8 201018567 121, the mold core 120 has a second molding surface: the shape and size of the molding surface 121 and the first mold surface n" Mesh: The forming surface 121 is also rectangular, the second forming ® (2) length = ... 〇 mm, and the width is also slightly larger than 26 〇 mm. In the second molding == there are a plurality of second molding portions 122. The plurality of second molding portions 122 m1 are arranged in an array. Each of the second forming dies 122 is =: the non-spherical curved surface of the molding surface m which is opened in the second mold core 12G
U二成型部m於第二成型面121上之開口為圓形， 型部122之於第二成型面121之開口大小與凹陷之 率應滿足待成型鏡片卩車列中鏡片之光學要求。每個第二 成型部122之直徑約為2毫米，每相鄰之兩個第二成型部 U之中心間距約為4毫米，於第二成型面i2i共形成有 6175個第二成型部。每個第二成型 型部如相對應。第二成型面121亦可為=、。個第成The opening of the U two forming portion m on the second molding surface 121 is circular, and the opening size and the recess ratio of the molding portion 122 to the second molding surface 121 should satisfy the optical requirements of the lens in the lens array to be formed. Each of the second molding portions 122 has a diameter of about 2 mm, a center-to-center spacing of each of the two adjacent second molding portions U is about 4 mm, and a total of 6175 second molding portions are formed on the second molding surface i2i. Each of the second molding portions corresponds to each other. The second molding surface 121 may also be =. First
第一模仁110之第一成型面m、形成於第一成型面 之第成型部112、第二模仁120之第二成型面121以 =成於第—模仁面12ι之第二成型部均經過超精密加工 製第一模仁110之材質通常為硬質金屬，本實施例中， 第:模仁110與第二模仁12〇由鋼製成。於超精細加工時， 可採用磨削加工法，即採用精密磨粒之砂輪或沙帶進行磨 削與研、拋，以使第一成型面ln與第二成型面121加工 精度小於0.3微米，第一成型面ηι與第二成型面121之粗 縫度小於〇.〇3微米。 當然，該射出成型模具100還可進一步包括對應配合 201018567 之第一模板（圖未示）與第二模板（圖未示），第一模板用 '於安裝第一模仁110，第二模板用於安裝第二模仁12〇。從 .而該射出成型模具100合模時，第一模板、第二模板、第 模仁110及第二模仁12〇可形成封閉之成型腔。 請參閱圖6’採用上述模具100射出成型鏡片陣列可採 用如下步驟： 第一步，將模具100安裝於射出成型機台。 第二步’使射出成型模具100合模，即，使第一模仁 110與第一模仁120相對靠近，使多個第一成型部112與多 個第一成型部122相對應，並使第一成型面in與第二成 型面121形成成型腔13〇。該成型腔130用於成型鏡片陣列。 本實施例中，模具100合模後，第一模仁面ηι與第 二模仁面121之間距為〇.4毫米至2毫米之間。 第三步，使鏡片材料以大於1〇〇〇毫米/秒之注射速度射 入成型腔130中。 _ 鏡片陣列200可採用聚曱基丙烯酸曱酯（pMMA)、聚 碳酸酯（PC)或聚苯乙烯（PS)等鏡片材料製成。進行射 出成型時，使得上述材料轉化為液態或溶融態，經過喷搶， 以大於1 〇〇〇毫米/秒之注射速度射入第一模仁與第二模 仁120構成之成型穴130中，從而可使鏡片材料充分填充 於成型腔130中，避免了成型腔130内出現填充不滿之問 題。 第四步，固化鏡片材料，以成型鏡片陣列2〇〇。 鏡片材料射入成型穴後，先冷卻鏡片材料，使鏡片材 201018567 料固化，從而形成鏡片陣列删。然後，使射出成型模具 100開模’即’使第-模仁道與第二模仁相對遠離/ 分離，從而將成型之鏡片陣列200從第一模仁110與第二 模仁120之間取出。 、 成型之鏡片陣列200包括基體201與複數陣列排布之 鏡片202 ’每個鏡片202均具有第一光學部2〇3與第二光學 邛204。基體201具有第一表面2〇11及與第一表面如^相 對之第二表面2012,第一表面2〇11與第二表面2〇12之間 距與合模時第一成型面與第二成型面121間距L相對 應’即於0.4毫米至2毫米之間。本實施例中，複數第一光 予P 203由複數第一成型部成型而成。第一光學部2〇3 之，狀與第一成型部112之凹陷之形狀相對應，故每個第 一光學部203均為自第一表面2〇1遠離鏡片陣列2〇〇之凸 起，其表面為非球形曲面。每個第二光學部2〇4由每個第 •y成型部122成型而成。第二光學部2〇4之形狀與第二成 瘳Ϊ«卩122之凹陷之形狀相對應，故每個第二光學部均 為自第二表面2012向遠離鏡片陣列200之凸起，其表面為 非球型曲面。由於合模時第一成型部112與第二成型部122 相對應，因此’鏡片陣列2〇〇中，第一光學部2〇3之中心 與第二光學部204之中心相對應，確保了鏡片202之光軸 為通過第一光學部203之中心與第二光學部2〇4之中心之 一條直線。 本技術方案之射出成型模具與鏡片陣列之射出成型方 法具有如下優點：首先’一次射出成型即可製造包括數以 11 201018567 千計之光學鏡片之鏡片陣列，可大大提升鏡片製作之速度 ‘ 與效率。其次’相較於壓印製程具有較低之生產成本。 綜上所述，本發明確已符合發明專利之要件，遂依法 提出專利申請。惟，以上所述者僅為本發明之較佳實施方 式，自不能以此限制本案之申請專利範圍。舉凡熟悉本案 技藝之人士援依本發明之精神所作之等效修飾或變化，皆 應涵蓋於以下申請專利範圍内。 【圖式簡單說明】 圖1係本技術方案實施例模具之部分示意圖 圖2係本技術方案實施例採用之第一模仁之部分示意 圖。 圖3係圖1沿ΙΠ_ΙΠ線之剖面示意圖。 圖4係本技術方案實施例採用之第二模仁之部分示意 圖。 圖5係圖4沿V-V線之剖面示意圖。 〇 圖6係本技術方案成型鏡片陣列時之示意圖。 【主要元件符號說明】 模具 100 第一模仁 110 第一成型面 111 第一成型部 112 第二模仁 120 第二成型面 121 12 201018567 第二成型部 122 成型腔 130 鏡片陣列 200 基體 201 第一表面 2011 第二表面 2012 鏡片 202 第一光學部 203 第二光學部 204The first molding surface m of the first mold core 110, the first molding surface 112 formed on the first molding surface, and the second molding surface 121 of the second mold core 120 are formed into a second molding portion of the first mold core surface 12i. The material of the first mold core 110 which is subjected to ultra-precision processing is usually a hard metal. In this embodiment, the first mold core 110 and the second mold core 12 are made of steel. In the case of ultra-fine processing, grinding, grinding or grinding, using a grinding wheel or a sand belt of precision abrasive grains, so that the first forming surface ln and the second forming surface 121 have a processing precision of less than 0.3 μm, The roughness of the first molding surface ηι and the second molding surface 121 is less than 〇.〇3 μm. Of course, the injection molding die 100 may further include a first template (not shown) corresponding to 201018567 and a second template (not shown), the first template is used to install the first mold core 110, and the second template is used for Install the second mold core 12〇. When the injection molding die 100 is closed, the first template, the second template, the first mold core 110 and the second mold core 12 can form a closed molding cavity. Referring to Fig. 6', the injection of the molded lens array using the above mold 100 can be carried out as follows: In the first step, the mold 100 is mounted on an injection molding machine. In the second step, the injection molding die 100 is clamped, that is, the first mold core 110 is relatively close to the first mold core 120, so that the plurality of first molding portions 112 correspond to the plurality of first molding portions 122, and The first molding surface in and the second molding surface 121 form a molding cavity 13A. The molding cavity 130 is used to form a lens array. In this embodiment, after the mold 100 is clamped, the distance between the first mold surface ηι and the second mold core surface 121 is between 0.4 mm and 2 mm. In the third step, the lens material is injected into the molding cavity 130 at an injection speed of more than 1 mm/sec. _ The lens array 200 can be made of a lens material such as poly(mercapto acrylate) (pMMA), polycarbonate (PC) or polystyrene (PS). When performing injection molding, the material is converted into a liquid or molten state, and after being sprayed, it is injected into the molding cavity 130 formed by the first mold core and the second mold core 120 at an injection speed of more than 1 mm/sec. Thereby, the lens material can be sufficiently filled in the molding cavity 130, and the problem of filling dissatisfaction in the molding cavity 130 is avoided. In the fourth step, the lens material is cured to form a lens array 2〇〇. After the lens material is injected into the forming hole, the lens material is cooled first, so that the lens material 201018567 is solidified, thereby forming a lens array. Then, the injection molding die 100 is opened, i.e., the first die channel and the second die are relatively separated/separated, whereby the molded lens array 200 is taken out between the first die 110 and the second die 120. The molded lens array 200 includes a substrate 201 and a plurality of arrays of lenses 202' each having a first optical portion 2〇3 and a second optical unit 204. The base body 201 has a first surface 2〇11 and a second surface 2012 opposite to the first surface, a distance between the first surface 2〇11 and the second surface 2〇12, and a first molding surface and a second molding when the mold is closed. The spacing 121 of the faces 121 corresponds to 'between 0.4 mm and 2 mm. In this embodiment, the plurality of first light P 203 is formed by a plurality of first molding portions. The shape of the first optical portion 2〇3 corresponds to the shape of the recess of the first molding portion 112, so each of the first optical portions 203 is a protrusion that is away from the lens array 2〇〇 from the first surface 2〇1. Its surface is a non-spherical surface. Each of the second optical portions 2〇4 is formed by each of the first y molding portions 122. The shape of the second optical portion 2〇4 corresponds to the shape of the recess of the second forming layer 卩122, so that each of the second optical portions is convex from the second surface 2012 away from the lens array 200, the surface thereof It is an aspherical surface. Since the first molding portion 112 corresponds to the second molding portion 122 at the time of mold clamping, the center of the first optical portion 2〇3 corresponds to the center of the second optical portion 204 in the lens array 2, and the lens is secured. The optical axis of 202 is a straight line passing through the center of the first optical portion 203 and the center of the second optical portion 2〇4. The injection molding method of the injection molding die and the lens array of the present technical solution has the following advantages: First, a lens array including 11 201018567 thousand optical lenses can be manufactured by one injection molding, which can greatly improve the speed of lens manufacturing and efficiency. . Secondly, there is a lower production cost compared to the imprint process. In summary, the present invention has indeed met the requirements of the invention patent, and has filed a patent application according to law. However, the above description is only a preferred embodiment of the present invention, and it is not possible to limit the scope of the patent application of the present invention. Equivalent modifications or variations made by persons skilled in the art in light of the present invention are intended to be included within the scope of the following claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial schematic view of a mold of an embodiment of the present technical solution. FIG. 2 is a partial schematic view of a first mold core used in an embodiment of the present technical solution. Figure 3 is a schematic cross-sectional view of Figure 1 along the ΙΠ_ΙΠ line. Fig. 4 is a partial schematic view showing a second mold core used in the embodiment of the present technical solution. Figure 5 is a schematic cross-sectional view taken along line V-V of Figure 4. 〇 Figure 6 is a schematic view of the present invention when forming a lens array. [Main component symbol description] Mold 100 First mold core 110 First molding surface 111 First molding portion 112 Second mold core 120 Second molding surface 121 12 201018567 Second molding portion 122 Molding cavity 130 Lens array 200 Base 201 First Surface 2011 second surface 2012 lens 202 first optical portion 203 second optical portion 204
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