TW201409085A - Lens array, lens arrange manufacturing method and optical element manufacturing method - Google Patents

Abstract

Provided are a lens array, a lens arrange manufacturing method and an optical element manufacturing method which enable production of optical elements at low cost in large quantities. This lens array is provided with multiple lens units aligned in an array, and is further provided with a resin lens layer formed such that the multiple lens units and recesses surrounding each of said lens units are formed integrally, and with an adhesive sheet detachably joined to the lens layer, wherein the lens layer is joined to the adhesive sheet in a state allowing individual detachment with the recesses as the boundaries.

Description

Lens array, method of manufacturing lens array, and method of manufacturing optical element

The present invention relates to a lens array, a method of manufacturing a lens array, and a method of manufacturing an optical element, and more particularly to a lens array, a method of manufacturing a lens array, and a method of manufacturing an optical element, which are suitable for mass production of optical elements.

For example, in the state in which the lens for the imaging device is mounted, the welding when the external terminal of the module is connected to another circuit board is automatically mounted by using the reflow step, so that work efficiency can be improved. In order to be able to withstand reflow soldering, a lens having sufficient heat resistance is required. Specifically, the temperature in the reflow furnace is set to 260 ° C or higher in order to promote remelting of the solder, and then the solder component is solidified with the temperature decrease, and the external terminal (electrical contact) of the module is connected to The conductor pads on the electronic circuit board also achieve a mechanical connection. Based on the above prior art, there is a growing demand for a lens having sufficient heat resistance against reflow soldering. On the other hand, it is also desired to manufacture a large number of lenses at low cost. A wafer-level lens array in which a plurality of lenses are formed on a lens substrate is known as a method of manufacturing a plurality of lenses at low cost. The method of cutting the lens substrate to separate the plurality of lenses to mass-produce the lens module.

For example, Patent Document 1 proposes a joint type composite lens in which a lens formed of a curable resin material is directly bonded to both surfaces of a lens formed of optical glass. However, this method is a structure in which the curable resin material is adhered to the surface of the glass, and it is necessary to use a cutting blade with a cutting blade when the lens is formed into a sheet. The cutting system requires a dedicated device, and the tact takes about ten minutes, resulting in high cost. In addition, since dust is generated during cutting, it must be washed after cutting, and if it is to be removed by dust of a micron size, relatively advanced equipment is required, resulting in higher cost.

Further, in recent years, although the improvement of the imaging performance of a camera-equipped mobile terminal or the like is remarkable, particularly in the case where the subject is dark, it is difficult to capture a clear image. Therefore, recently, an auxiliary light source unit such as a flash has gradually developed a method of emitting auxiliary light toward a subject. As the auxiliary light source unit, for example, an LED is used as a light source, and the emitted light from the LED is passed through the lens to control the illumination angle, and the range of the subject suitable for imaging is illuminated. However, it can be said that when a lens is manufactured at a low cost, it is desirable to form a resin by molding a resin material. Here, in a method of manufacturing a plurality of lenses at low cost, a wafer-level lens array in which a plurality of lenses are formed on a lens substrate is known, and the lens substrate is cut to separate the plurality of lenses to thereby measure the amount of the lens module. Production method. For example, Patent Document 3 proposes: after forming a wafer-level lens array and laminating it through a spacer, cutting is performed to give a lens Slice method.

An image pickup device called a camera module is mounted on a mobile terminal and is mounted on a mobile terminal that is a small and thin electronic device such as a mobile phone or a PDA (Personal Digital Assistant). Can be transmitted to each other in the distance. In the image pickup device used in the image pickup device, a solid-state image sensor such as a CCD image sensor or a CMOS image sensor is used, and in recent years, the image sensor has been increased in pixel size, and high resolution and high resolution have been sought. Performance. On the other hand, in order to reduce the cost, a lens for imaging which is formed on an image pickup element such as a subject image is processed by using a lens formed of a resin material which can be mass-produced at a low price. The properties are also good and the aspherical shape is obtained, which is compatible with the requirements for high performance. In addition, the lens used for the auxiliary light source unit of the mobile terminal is also expected to be manufactured with high precision and at low cost. Here, a method of manufacturing a plurality of lenses at low cost is known, and a lens array in which a plurality of lenses are formed on a parallel plane glass plate is known, and a method of cutting the glass plates to separate the plurality of lenses to mass-produce the lenses is known. . For example, Patent Document 1 proposes a method of forming a lens array by the above-described manufacturing method, and performing dicing to form a lens.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent No. 3926380

[Patent Document 2] Japanese Patent Laid-Open Publication No. 2009-084442

[Patent Document 3] Japanese Patent Laid-Open Publication No. 2011-113075

[Patent Document 4] Japanese Patent Laid-Open Publication No. 2002-264140

Patent Document 2 proposes a step of half-cutting a multilayer sheet. The position at which the cutting position is determined is a method in which a hole for determining the position is additionally provided, and the hole is used as a determined position to pass the pin and then cut. However, there is a need to determine the position drilling, and it is necessary to determine the position drilling. The blade and the problem of the position pin need to be determined on the side of the semi-cutting edge, which complicates the steps and heightens the necessary components and devices. In addition, if the steps are added, it is determined that the position tends to be poor due to the overlap. In addition, there is a need for a space for holes and pins, and there is a problem that a waste portion is generated on the product. Further, Patent Document 2 does not correspond to a manufacturer of a lens which is necessary for high precision.

In the case where the cutting device as in Patent Documents 1 and 3 is large-scale and expensive, and it is necessary to determine the position with high precision, the step is complicated by the addition of the mechanism and the price is increased. The cutting step itself is also performed in a row-by-row manner, so that it takes time to give an excessive influence on productivity, and the cutting pattern is substantially limited to a lattice shape, so that there is a problem that the lens shape is limited. In addition to this, fine chips are generated during the cutting, so the washing step becomes indispensable, and the washing liquid is also consumed as a consumable and must be handled with great care. That is, the lens manufactured by the techniques of Patent Documents 1 and 3 is inferior in productivity and causes an increase in cost. In addition to this In addition, by cutting the cut lens, the following problems occur when combined with a light source. Recently, the number of pixels of the image pickup device has become an advanced development as in the case of 8 million pixels and 12 million pixels. In the auxiliary light source unit, the eccentricity accuracy of the optical axis of the lens and the center of the light source also needs to be improved. However, in the shape of the lens which is sliced by dicing, since a certain degree of error occurs depending on the thickness of the blade of the dicing blade, etc., when the lens is assembled with the light source, the lens profile is taken as When the reference position is determined, an eccentricity is generated between the optical axis of the lens and the center of the light source, and the product that does not conform to the specification increases, which is an important cause of deterioration in yield.

With respect to the techniques of Patent Documents 1 and 3, based on the point of view that is completely different from the prior art, attempts have been made to cut the lens array by cutting it off without undue mentality. However, the present inventors have found that even if the lens portion can be sliced by cutting the lens array, depending on the condition of the resin, cracks or chips may be generated at the cut surface due to the fragility thereof. Produces a flaw in appearance. Further, the inventors have found that dust adheres to the surface of the lens at the time of cutting, and this causes a further appearance defect. However, even if it is desired to solve the problem by the improvement of the resin, in the prior art, no specific solution strategy has been disclosed. For example, in Patent Document 4, a resin for molding a Fresnel lens has a content in which a surfactant is added to a thermosetting resin, but there is no mention about the use or content thereof. Basically, the Fresnel lens is not intended to be manufactured by cutting.

The present invention has been completed in view of the problems of the prior art. The object of the invention is to provide a lens array capable of mass-producing optical elements at low cost, a method of manufacturing a lens array, and a method of manufacturing an optical element.

The lens array according to the first aspect of the invention includes the plurality of lens portions arranged in an array, and the resin lens layer integrally formed by the plurality of lens portions and the concave portion surrounding the periphery of each of the lens portions And an adhesive sheet that can be detachably bonded to the lens layer, wherein the lens layer is bonded to the adhesive sheet in a state in which the concave portions are bounded by the concave portion.

In the lens array according to the first aspect of the invention, the concave portion has a groove having a V-shaped cross section at the bottom, and the groove is formed in a severable manner.

The lens array according to claim 3, wherein in the invention of claim 2, the angle of the V-shaped cross section of the recess is 20 to 60 degrees.

The lens array according to claim 4, wherein in the invention of claim 2 or 3, the minimum thickness of the lens array at the bottom of the trench is 20 μm to 150 μm.

The lens array according to any one of claims 2 to 4, wherein the concave portion further has a reference surface for determining a position, and the lens portion and the reference The dough is integrally formed by a mold.

Applying the lens array described in item 6 of the patent scope, In the invention of claim 5, the reference surface is formed by a slope of the groove of the V-shaped cross section.

In the lens array according to claim 5, in the invention of claim 5, the reference surface is formed by a notch formed adjacent to the groove.

In the lens array according to any one of the second to seventh aspects of the invention, the resin constituting the lens array is an energy curable resin.

In the invention of any one of the second to eighth aspects of the invention, the lens layer is an energy for forming an energy curable resin composition by using a mold. The energy curable resin composition contains a polymerizable monomer and a functional group having a chemical reaction with a functional group of the polymerizable composition to form a bond, and has a number average molecular weight of 1,000 to 50,000. Modification of polyoxane.

The lens array according to claim 10, wherein in the invention of claim 9, the average molecular weight of the modified polysiloxane coefficient is from 1,000 to 30,000.

The lens array according to claim 11, wherein in the invention of claim 9 or 10, the content of the modified polyfluorene oxide in the energy curable resin composition is 0.5 to 10% by weight. .

The lens array according to claim 12, wherein in the invention of any one of claim 9 to 11, the aforementioned The modified polyoxygenated system has a functional group having two or more functional groups.

In the invention of any one of the inventions, the energy curable resin is an ultraviolet curable resin or a thermosetting resin.

In the invention according to any one of claims 9 to 13, wherein the energy curable resin is an epoxy energy curable resin or an acrylic energy hardening. Resin.

The lens array according to claim 15 of the invention, wherein in the lens layer, a cut portion is formed in a bottom portion of the concave portion, and at least a part of the cut portion reaches the adhesive sheet. However, it does not penetrate the aforementioned adhesive sheet.

The lens array according to claim 16 of the invention, wherein the lens layer has a V groove in the concave portion, the V groove has an angle of 30° to 60°, and the cutting in The part is formed at the bottom of the aforementioned V-groove.

In the lens array according to the fifteenth or sixteenth aspect of the invention, the resin constituting the lens array is an energy curable resin.

The lens array according to any one of claims 15 to 17, wherein the adhesive sheet and the lens layer have a resin layer, and the cut-in portion penetrates through the foregoing The resin layer does not penetrate the aforementioned adhesive sheet.

Applying for the lens array described in item 19 of the patent scope, In the invention of claim 18, the surface of the resin layer opposite to the lens layer is coated with a transparent inorganic layer.

The lens array according to any one of claims 1 to 19, wherein the lens portions are arranged in a line.

The lens array according to any one of claims 1 to 20, wherein the lens portion has a blaze shape in the optical axis direction.

The lens array according to any one of the first to twenty-first aspects of the invention, wherein the back surface of the lens portion is a flat surface.

The method for producing a lens array according to claim 23, wherein the method of manufacturing a lens array having a resin lens layer in which a plurality of lens portions arranged in an array are formed is characterized in that a mold having a transfer surface is used The resin is molded and released from the mold to form the lens layer, and the transfer surface includes a first portion corresponding to the plurality of lens portions and a convex second portion surrounding the periphery of the first portion, and is capable of being mounted The detached adhesive sheet is bonded to the molded article, and each of the lens portions of the lens layer to which the adhesive sheet is bonded is in a state of being detachable from each other by the concave portion.

The method of manufacturing a lens array according to claim 24, wherein in the invention of claim 23, the recessed portion having a depth that can be cut is formed by the forming, whereby the lens layer to which the adhesive sheet is bonded is formed Each of the lens portions is defined by the concave portion A state that can be separated from each other.

The method of manufacturing a lens array according to claim 25, wherein in the invention of claim 23, the cutting blade is inserted while being guided by the groove, and at least a part of the adhesive sheet is reached. The cut portion is formed so as not to penetrate the adhesive sheet, so that the respective lens portions of the lens layer can be separated from each other by the concave portion.

The method of manufacturing an optical element according to claim 26, wherein the lens array according to any one of claims 2 to 14 is cut along the groove, and each of the lenses is The Ministry will be sliced.

In the invention of claim 26, in the invention of claim 26, the cutting is performed by applying a force to the lens array in a direction in which the adjacent lens portions are separated from each other.

The method of producing an optical element according to the invention of claim 28, wherein the lens layer is peeled off from the adhesive sheet of the lens array according to any one of claims 15 to 18.

Next, a preferred configuration of the present invention will be described.

The lens array of the present invention is a lens array sheet comprising a resin lens layer formed with a plurality of lens portions arranged in an array and a resin base layer bonded to the lens layer, wherein the lens layer is a cut-in portion is formed around the lens portion, and at least one portion is formed The aforementioned cut-in portion reaches the base layer but does not penetrate the base layer.

When the lens array disclosed in Patent Document 1 or the like is used, since a large number of lenses can be temporarily produced, productivity is excellent. However, cutting must be performed when such a lens array is sliced. Since the cutting is performed after the position of the alignment symbol or the like is recognized and the position is determined, the case where the dicer is required to determine the position function by the alignment symbol, and the case where the cutting is performed line by line to extend the working time, In addition, it is necessary to wash the chips, and the main reason for hindering productivity.

On the other hand, according to the present invention, the lens layer is formed with a cut portion around the lens portion, and at least a part of the cut portion reaches the base layer, but the base portion is not penetrated. The base layer can be held by almost only the adhesive force therebetween, whereby the lens layer can be easily peeled off into each of the lens portions, so that the sheet can be accurately prepared with a short working time. It is advantageous in terms of eliminating the washing step, and it is possible to mass-produce optical components at low cost.

The lens layer has a V-groove formed around the lens portion, and the V-groove has an angle of 30 to 60°, and the cut-in portion is preferably formed at a bottom portion of the V-groove. When the V-groove is formed around the lens portion, and the angle of the V-groove is 30 to 60°, the cutting blade inserted into the V-groove can be smoothly guided, thereby ensuring the determination position of the number μ scale. Accuracy, at the same time can form the aforementioned cut-in portion.

The outer shape of the lens portion is preferably a circular shape. Due to the foregoing Since the outer shape of the lens portion is smooth, there is an advantage that it is less likely to be cracked by a punching step, a thermal shock, or the like, and the image unit or the like is excellent in strength when modularized.

The shape of the aforementioned lens portion is preferably a rectangle. Thereby, the outer shape of the adjacent lens portions can be made uniform. Therefore, it is preferable that no material is wasted after cutting out the lens array sheet. In addition, there is an advantage that the light that passes through is irradiated in a square shape and is easily controlled.

The shape of the aforementioned lens portion is preferably a polygonal shape. Thereby, the outer shape of the adjacent lens portions can be made uniform, and it is preferable that the raw material is not wasted after the lens array sheet is cut out. Further, it has an advantage that the light that passes through is irradiated in a polygonal shape and is easily controlled.

It is preferable that the aforementioned lens portions are arranged in a line. Thereby, the same processing as the semiconductor assembly step can be performed, and the lens portion can be taken out from the lens array sheet by the robot.

It is preferable that the lens portions are arranged in a lattice shape. A large number of lens portions can be taken out from one lens array sheet, and productivity can be improved to reduce cost.

The lens portions are arranged in a plurality of rows, and the lens portions of the adjacent rows are preferably interlaced in the column direction. In the application of the resin coating and molding apparatus, it is sometimes desirable to make the outer shape of the lens array sheet nearly circular. In this case, if the lens portions are arranged in a plurality of rows and the lens portions of the adjacent columns are staggered in the column direction, the number of lens portions in one lens array sheet can be increased, and production can be performed. Increased sexuality and reduced costs.

The lens layer is preferably formed of an energy curable resin. The energy curable resin represented by the ultraviolet curable resin or the thermosetting resin is excellent in reflow resistance and environmental reliability. In addition, even if the optical surface accuracy is low, the shrinkage rate is low, and a lens surface with good precision can be formed.

The aforementioned substrate layer is preferably one layer. As a result, the optical element is a monolithic optical element, and since it does not have an interface in the optical axis direction, it is excellent in optical characteristics. In addition, since there is no peeling at the interface, the environmental reliability is also improved. Further, shrinkage deformation and warpage at the time of molding can be prevented.

The base layer is preferably formed of any one of a polyimide resin, TAC, PET, an acrylic resin, and an epoxy resin. These materials are heat-resistant, and in the case where annealing is required after molding, the lens portion can be formed in a state of the lens array sheet without being formed into a sheet. Further, since the lens portion can be formed, cut, annealed, inspected, or even shipped in the same manner, the productivity is excellent.

The base layer has a first resin layer and a second resin layer, and the cut portion penetrates the first resin layer, but it is preferably not penetrated through the second resin layer. In this case, the lens portion is a two-layered lens. However, when used in, for example, an auxiliary light source unit, a material having a small amount of exhaust gas and high environmental reliability can be used for the second resin layer close to the light source. Improve the reliability of the auxiliary light source unit.

In the first resin layer of the underlayer, it is preferable that a surface of the opposite side of the lens layer is coated with a transparent inorganic layer. By coating the surface side of the first resin layer opposite to the lens layer, the coating is transparent The inorganic layer can be prevented from being vented when the optical element is disposed in front of the light-emitting element. The transparent inorganic layer means having glass, DLC (Drilling Carbon), or the like.

The second resin layer of the underlayer is preferably formed of any one of a polyimide resin, TAC, PET, an acrylic resin, and an epoxy resin. These materials are heat-resistant, and in the case where annealing is required after molding, the lens portion can be formed in a state of the lens array sheet without being formed into a sheet. Further, since the lens portion can be formed, cut, annealed, inspected, or even shipped in the same manner, the productivity is excellent. Further, the base layer can be extended to remove the lens portion, and the same system as the conventional semiconductor assembly step can be used.

The optical element manufacturing method of the present invention is obtained by cutting a lens array sheet formed of a resin lens layer formed with a plurality of lens portions arranged in an array and a resin base layer bonded to the lens layer. Each of the methods for forming an optical element for forming an optical element, comprising: providing a lens material on the base layer and pressing a mold, thereby forming a groove around each lens portion together with the plurality of lens portions a step of inserting a cutting blade while guiding the groove, and at least partially reaching the base layer, but forming a cut portion so as not to penetrate the base layer, and cutting away from each of the cut portions The step of the aforementioned lens portion.

According to the present invention, the cutting blade is inserted while guiding the groove, whereby the cut portion having the position with high accuracy can be formed. Further, a cut-in portion is formed in the lens layer, at least a part of The cutting portion reaches the base layer, but does not penetrate the base layer. Therefore, the lens portion can be held by the adhesion between the base layer and the base layer, whereby the lens layer can be easily peeled off. Each of the lens portions can be accurately sliced with a short working time, and is advantageous in terms of eliminating the washing step, and can mass-produce the optical element at low cost.

The cutting blade is relatively movable in the direction intersecting with the insertion direction, and the cutting blade has a front end angle of 20 to 55° and a smaller angle of 5° or more from the V groove angle. It is better. By making the front end angle of the cutting blade smaller than the V groove angle by 5° or more, it is easy to insert into the V groove, and even if the cutting blade front end position is slightly offset, the cutting blade will follow Guided by the wall surface of the V-groove and smoothly guided to the cutting position, the positional accuracy of the number of μ scales can be ensured. Further, the durability of the blade can be ensured by setting the tip end angle of the cutting blade to 20° or more.

A representative example of the shape of the lens portion may be a free curved surface exhibited by a blaze shape, an aspherical surface, a deformed surface, and a polynomial. In addition, the size of the lens portion is 0.5~5mm is preferred. The thickness is preferably in a range in which the maximum thickness is set to 0.05 to 1 mm. The material of the lens layer is a curable resin material which is transparent after curing such as a photocurable resin material or a thermosetting resin material. Specifically, an epoxy resin or an acrylic resin which is cured by heat or ultraviolet rays is preferably used. By constituting the lens portion with such a curable resin, it is possible to provide optical performance and to have reflow resistance and thermal shock resistance. The difference in linear expansion coefficient from the underlayer (the first resin layer in the case of two layers) is preferably 100 × 10 ^-6 or less. Further, the difference in linear expansion coefficient from the underlayer (the first resin layer in the case of two layers) is preferably 50 × 10 ^-6 or less.

It is preferable that the first resin layer on the lens layer side when the base layer is two layers is made of a polyimide having transparency. This resin has both heat resistance and transparency, and the difference from the linear expansion property of the lens portion composed of the energy curable resin is smaller than that of the glass, and the hygroscopicity is lower than that of the acrylic resin. Therefore, the first resin layer as the optical element constituting the auxiliary light source unit is preferable. Commercially available, Neopulim manufactured by Mitsubishi Gas Chemical Co., Ltd., and LUCERA manufactured by JSR Co., Ltd. can be used. The smoothness of the side surface of the lens portion of the first resin layer is preferably a mirror surface having a Ra of 0.1 nm to 10 nm. Further, it is preferable that the smoothness of the side surface of the lens portion of the first resin layer is a surface having minute irregularities of Ra 0.1 μm to 10 μm, and the bonding force is increased by the anchoring effect. In terms of transparency of the first resin layer, the transmittance is preferably 85% or more in the visible light region. The thickness of the first resin layer is preferably 0.05 to 0.5 mm. In order to improve the adhesion to the lens portion in the first resin layer, it is preferred to perform pretreatment before forming the lens portion. Examples of the pretreatment include an activation treatment by ultraviolet irradiation, ozone by the ultraviolet light, an oxygen plasma treatment such as corona discharge, an activation treatment by ion etching, an oxygen coupling treatment, and the like. . The light emitting element comprises an LED. The base layer (the second resin layer when the two layers are provided) is preferably formed of a polyimide resin, TAC or PET, or an acrylic resin or an epoxy resin.

The lens array of the present invention is used to manufacture and assemble A resin lens array in which an optical element of an auxiliary light source unit is formed and a plurality of lens portions arranged in an array are formed, wherein at least a V-shaped cross section is formed between the adjacent lens portions. The groove and the reference surface for determining the position, and the lens portion and the reference surface are integrally formed by a mold.

According to the invention, in the lens array, a groove having at least a V-shaped cross section is formed between the adjacent lens portions. Therefore, the bottom of the groove can be used as a starting point to cut the resin. In the lens array described above, it is easy to realize the singulation of the aforementioned lens portion at low cost without depending on the dicing.

Here, when the lens portion is formed into a sheet, it is considered that, for example, cutting is performed along the groove. However, if the lens portion is cut away from the lens portion, a burr is generated, and thus the burr is used. When the cut surface is used as the reference surface for determining the position, the position is determined by the burrs, and it is difficult to use the cut surface as the reference surface for determining the position. Further, when the width of the groove is increased and the space for cutting processing (about 100 μm) is further provided, an unnecessary portion is increased. Therefore, the outer diameter of each of the lens portions is restricted, or if the outer diameter of the lens portion is sufficiently secured, the size of each of the lens portions is increased, and the overall size of the lens array is increased, and productivity is deteriorated. The problem. If an unnecessary portion is added, the amount of raw material used is increased. Therefore, when a relatively expensive energy-curable resin is used, there is also a problem that the unit price of the lens is increased. On the other hand, according to the present invention, the lens array can be cut by using the bottom of the groove as a starting point, thereby being solvable The above two questions are resolved. Further, since the cutting is not performed, it is not necessary to perform a precise and expensive cutting device which is performed after the symbol of the alignment symbol or the like is recognized and the position is determined, and the long working time of the cutting process which must be cut one by one can be avoided. Further, since it is not necessary to clean the chips generated by the cutting process (the washing liquid is discarded), the advantage of productivity improvement can be obtained.

Further, when the auxiliary light source unit is formed by combining the lens portion which is formed by dicing the lens array along the groove and the auxiliary light source, the lens portion and the reference surface are integrally formed by a mold, and therefore, The predetermined reference surface is used to accurately determine the position of the lens portion and the auxiliary light source.

The corner angle in the V-shaped cross section of the groove is preferably 20° to 60°. Here, the angular condition of the above-mentioned corner is defined in order to perform cutting with high precision. When the corner angle is 20 or more, the convex transfer portion of the mold for molding the groove does not become too thin, and the strength and durability of the mold can be ensured. On the other hand, if the corner angle is 60 or less, the projected area of the groove in the optical axis direction does not become excessively large, and it is not necessary to limit the outer diameter of the lens portion, and further, the sheet is cut by cutting. At the time of the formation, the portion in which the groove is deviated from the innermost portion is less likely to be cut, and the cross section is likely to be sharp. Further, although the mold used for molding may be made of a low-cost resin, the use time may be shortened compared to a metal mold, and therefore it is desirable to increase the lower limit of the above-described corner angle (for example, 30° or more) to ensure durability.

The aforementioned reference plane is inclined by the groove of the aforementioned V-shaped cross section The composition of the face is better. Thereby, the mold release property of the mold is improved, and the formation of the aforementioned lens array is facilitated.

Preferably, the reference surface is formed by a notch formed adjacent to the groove. When the reference plane is a notch surface different from the V-shaped cross section, for example, an optical axis parallel surface, after the lens array is formed into a sheet, it is easy to hold the lens portion of a small size by the reference surface, and assembly is possible. Excellent.

The minimum thickness of the aforementioned lens array at the bottom of the aforementioned trench is preferably 20 μm to 150 μm. When the minimum thickness of the lens array is 20 μm or more, when the lens array is released from the mold or during transportation, the lens array is not easily broken even if it is not intentionally applied to the lens array, and the handleability is excellent. On the other hand, when the minimum thickness of the lens array is 150 μm or less, when the lens array is sliced by cutting, the portion of the groove that is deviated from the innermost portion is less likely to be cut and has a cross section. It will easily become a sharp advantage.

The outer shape of the lens portion is preferably a circular shape. The emitted light can be controlled to have a circular shape by assembling the sliced lens portion to the auxiliary light source unit.

The shape of the aforementioned lens portion is preferably a rectangle. It is preferable that the emitted light is controlled in a rectangular shape by assembling the individualized lens portions to the auxiliary light source unit. Further, by singulating the aforementioned lens array, the amount of waste resin is reduced, and the cost can be reduced.

The shape of the aforementioned lens portion is preferably a polygonal shape. The lens can be emitted by assembling the singulated lens portion to the auxiliary light source unit The light is controlled into a polygonal shape.

It is preferable that the aforementioned lens portions are arranged in a line. Thereby, the lens portion can be manufactured in the same steps as the semiconductor assembly step, and the robot can be easily automated by using a robot or the like for holding the sliced lens portion.

It is preferable that the lens portions are arranged in a lattice shape. A large number of the aforementioned lens portions can be manufactured by one lens array, and the productivity is improved to reduce the cost.

The resin constituting the lens array is preferably an energy curable resin. The energy curable resin is excellent in heat resistance or environmental reliability required for the reflow step of mounting the lens portion together with the light source when the auxiliary light source unit is fabricated. Further, since the shrinkage ratio at the time of curing is low, it is also preferable from the viewpoint of ensuring the accuracy of the optical surface of the lens portion. Further, it also has an advantage of excellent cutting property.

The back surface of the lens portion is preferably a flat surface. Thereby, the shape of the mold can be simplified, and the cost can be reduced.

It is preferable to apply SiO ₂ to the plane portion. By performing SiO ₂ coating on the planar portion, it is possible to suppress the occurrence of exhaust gas after being assembled in the auxiliary light source unit, and to suppress the influence on the light source.

It is preferable to apply anti-reflection coating to the planar portion. By performing anti-reflection coating on the planar portion, the emitted light from the light source can be efficiently penetrated after being assembled in the auxiliary light source unit.

Preferably, the flexible resin sheet is adhered to the flat portion. By cutting the flexible resin sheet to the plane portion, by cutting When the lens array is formed into a sheet, the lens portion is not dispersed and falls, and the handleability is excellent.

A method of manufacturing a lens array according to the present invention is a method of manufacturing a lens array using an optical element incorporated in an auxiliary light source unit for imaging, characterized in that it has a lens transfer portion arranged in a lens shape and is provided on a step of disposing a molding material having a fluidity between the lens transfer portion and a facing mold, and a step of curing the resin material between the molding die and the opposing mold; The molding die is released from the opposing mold, and the lens portion having the lens transfer portion transferred by the lens transfer portion and the V-shaped cross section transferred by the front end side of the convex transfer portion are grooved. And a step of taking out the lens array on which the position of the reference surface transferred by the side surface of the convex transfer portion is removed.

According to the invention, in the lens array formed by curing the resin material having the fluidity described above, the convex portion is formed by the convex portion between the lens portions transferred by the lens transfer portion At least the bottom portion of the front end side is a groove having a V-shaped cross section. Therefore, the lens array can be cut by using the bottom of the groove as a starting point, thereby facilitating the realization of the lens portion at low cost without depending on cutting. Sliced.

Further, since the lens portion transferred by the lens transfer portion and the reference surface for determining the position transferred by the side surface of the convex transfer portion are integrally molded by the mold, the When the lens array is combined with the auxiliary light source to form the auxiliary light source unit along the groove array, the reference plane can be used to accurately determine the position of the lens portion and the auxiliary light source. .

Preferably, each of the aforementioned lens portions is sliced by cutting the lens array manufactured by the above-described manufacturing method along the groove. Since it is not necessary to rely on the cutting when the lens array is sliced, defects such as burrs are not generated.

The cutting is preferably performed by imparting force to the lens array in a direction in which the adjacent lens portions are separated from each other. Thereby, the cutting is caused at the bottom of the most fragile groove, and the aforementioned lens array can be easily sliced.

The auxiliary light source unit of the present invention is characterized in that the optical element and the auxiliary light source manufactured by the above-described manufacturing method are assembled using the reference surface to determine the position. This provides a low-cost auxiliary light source unit for high precision.

Another method of manufacturing a lens array according to the present invention is characterized in that: the energy curable resin composition is molded by using a mold to obtain a plurality of lens portions arranged in an array, and the adjacent lenses a step of forming a lens array made of an energy curable resin having a groove for cutting, the energy curable resin composition containing an energy curable resin composition of a polymerizable monomer, and having a polymerizable composition as described above The functional group of the substance chemically reacts to form a bonded functional group, and contains an energy curable resin composition of a modified polyfluorene oxide having a number average molecular weight of 1,000 to 50,000.

As a result of intensive studies, the present inventors have found that when the lens array is molded, a functional group which forms a bond by chemical reaction with a functional group of an energy curable resin is used, and the amount is flat. The energy curable resin having a modified molecular weight of 500 to 50,000, which imparts a molecular weight of 500 to 50,000, imparts flexibility to the energy curable resin to the modified polyfluorene, thereby improving chip resistance. Further, by adding the modified polyfluorene oxide, the conductivity of the surface of the lens array is improved, and the friction is weakened, whereby the static electricity is less likely to accumulate, and therefore the dust adhesion is also observed to be reduced.

That is, if the modified polyfluorene oxide has a functional group which chemically reacts with the functional group of the energy curable resin to form a bond, and the number average molecular weight is 500 to 50,000, since the modified polyfluorene is directly incorporated In the organic chain of the resin, the effect of imparting flexibility is increased. Further, the more the content of the modified polyfluorene oxygen and the number of functional groups, the easier it is to react with the resin functional group, and it is incorporated into the organic chain. Incidentally, if the number average molecular weight of the modified polyfluorene is less than 500, the resin is easily volatilized when it is cured, and a volatile component is generated to cause exhaust gas. On the other hand, if the number average molecular weight of the modified polyfluorene oxygen exceeds 50,000, the viscosity becomes high and the solubility of the resin is deteriorated. If the number average molecular weight of the modified polyfluorene is from 500 to 50,000, the defect can be suppressed.

The modified polyfluorinated oxygen system preferably has a number average molecular weight of from 1,000 to 30,000. This will further improve the characteristics of the debris and improve the dust adhesion reduction effect.

The content of the modified polyfluorene oxygen in the energy curable resin composition is preferably 0.5 to 10% by weight. When the content of the modified polyfluorene oxide is 0.5% by weight or more, sufficient flexibility of the resin can be ensured, and the effect of suppressing bubbles is also high. Therefore, it is effective particularly when a Fresnel lens or the like is formed. On the other hand, if the content of the modified polyfluorene is 10 When the weight is less than or equal to 100%, the heat resistance of the resin can be ensured. Therefore, it is suitable for, for example, a reflow step for mounting the lens portion together with the auxiliary light source or the image pickup element. Further, in the case of a lens used for the auxiliary light source unit, it is possible to withstand heat from the auxiliary light source.

The modified polyfluorinated oxygen is preferably a functional group having two or more functional groups. The more the content of the modified polyfluorene oxygen and the number of functional groups, the easier it is to react with the resin functional group, and the more it can be incorporated into the resin skeleton. However, excessive addition causes deterioration of heat resistance, and therefore, the content of the modified polyfluorene is preferably 10% by weight or less.

The energy curable resin is preferably an ultraviolet curable resin or a thermosetting resin. These resins are excellent in heat resistance and environmental reliability required for the reflow step of mounting the lens portion together with the image pickup element or the light source. Further, since the shrinkage ratio at the time of curing is low, it is also preferable from the viewpoint of ensuring the accuracy of the optical surface of the lens portion.

The energy curable resin is preferably an epoxy-based energy curable resin or an acrylic energy curable resin. These resins are excellent in optical characteristics and have advantages that are easily obtained.

The aforementioned mold system is preferably made of a resin. Thereby, since the mold can be transferred and formed from the master mold, only one master mold can be produced, and a plurality of molds can be reproduced, and the mold manufacturing cost can be reduced. Further, the aforementioned mold system is preferably made of PDMS.

It is preferable that the lens portion has a lightning-like cross section in the optical axis direction. According to the manufacturing method of the present invention, by the aforementioned energy hardening property The resin contains the modified polyfluorene oxygen, and can also be expected to have a bubble suppressing effect at the time of curing. Therefore, it is particularly suitable for a lens such as a Fresnel lens or the like, and has a lightning-like cross section in the optical axis direction.

The back surface side of the lens portion of the lens array is a flat surface, and it is preferable that the flexible resin sheet is adhered to the flat surface. When the flexible resin sheet is adhered to the flat surface and the lens array is formed by cutting, the lens portion is not dispersed and falls, and the handleability is excellent.

Preferably, each of the aforementioned lens portions is sliced by cutting the lens array manufactured by the above-described manufacturing method along the groove. By using the above-mentioned resin as a raw material, it is possible to suppress the generation of debris or dust at the time of cutting, and to manufacture an optical element in a large amount and at a low cost with a small number of engineering.

The cutting is preferably performed by imparting force to the lens array in a direction in which the adjacent lens portions are separated from each other. Thereby, the cutting is caused at the bottom of the most fragile groove, and the aforementioned lens array can be easily sliced.

The optical element of the present invention is characterized by being manufactured by the aforementioned manufacturing method.

<Energy Curable Resin>

As the energy curable resin, a photocurable resin or a thermosetting resin can be used.

[Photocurable resin or thermosetting resin]

Examples of the photocurable resin or the thermosetting resin include an acrylic resin, an allyl ester resin, a vinyl resin, an epoxy resin, and the like. The acrylic resin material or the allyl ester resin material or the ethylene resin material as the energy curable resin composition contains a polymerizable monomer which can be hardened by radical polymerization of a photopolymerization initiator and a photopolymerization initiation. Agent. Further, the epoxy resin material as the energy curable resin composition contains a polymerizable monomer and a photopolymerization initiator which can be cured by cationic polymerization or anionic polymerization of a photopolymerization initiator. Hereinafter, a polymerizable composition (resin material) and a photopolymerization initiator will be described.

1) Acrylic resin material

The type of the (meth) acrylate used as the acrylic resin material is not particularly limited. In the case of the (meth) acrylate, an ester (meth) acrylate, a urethane (meth) acrylate, an epoxy (meth) acrylate, an ether (meth) acrylate, an alkane may be contained. (meth) acrylate, alkyl (meth) acrylate, (meth) acrylate having an aromatic ring, polyfunctional (meth) acrylate, (meth) acrylate having an alicyclic structure . These may be used alone or in combination of two or more.

Among these, (meth) acrylate having an alicyclic structure is preferred. The alicyclic structure may also be an alicyclic structure containing an oxygen atom or a nitrogen atom. In the case of such a (meth) acrylate, it may include: cyclohexyl (meth) acrylate, cyclopentyl (meth) acrylate, cycloheptyl (meth) acrylate, bicycloheptyl (A) Acrylate, Tricyclodecyl (meth) acrylate, tricyclodecane dimethanol (meth) acrylate, or isodecyl (meth) acrylate, hydrogenated bisphenol bis (meth) acrylate, and the like. Further, among the (meth) acrylates having an alicyclic structure, those having an adamantane skeleton are particularly preferable. In the case of such a (meth) acrylate, 2-alkyl-2-adamantyl (meth) acrylate (refer to JP-A-2002-193883), adamantyl bis (methyl) Acrylate (refer to Japanese Laid-Open Patent Publication No. SHO 57-500785), adamantyl adamantyl dicarboxylate (refer to JP-A-60-100537), and perfluoroadamantyl acrylate (refer to Japanese special) JP-A-2004-123687), 2-methyl-2-adamantyl methacrylic acid (Xinzhongcun Chemical Industry Co., Ltd.), 1,3-adamantanediol diacrylate, 1,3,5-gold Alkanol triol triacrylate, unsaturated adamantyl carboxylate (refer to JP-A-2000-119220), 3,3'-dialkoxycarbonyl-1,1' bisadamantane (refer to Japan Special Edition) JP-A-2001-253835), 1,1'-bisadamantane compound (refer to the specification of U.S. Patent No. 3,342,880), tetraamantane (refer to JP-A-2006-169177), 2-alkyl-2-hydroxyaluminum A curable resin having an adamantane skeleton having no aromatic ring, such as an alkane, a 2-alkylalkyladamantane or a 1,3-adamantane dicarboxylic acid di-tert-butyl group (refer to Japanese Patent Laid-Open Publication No. 2001-322950) Reported), bis (hydroxyphenyl) adamantanes or bis (glycidyl oxyphenyl) adamantane (refer to Japanese Patent Laid-Open Publication No. 11-35522 and Japanese Patent Publication Laid-Open No. 10-130371) and the like.

Further, the acrylic resin material may contain other reactive monomers such as (meth) acrylate or polyfunctional (meth) acrylate. . In the case of such a (meth) acrylate, it includes: methacrylate, methyl methacrylate, n-butyl acrylate, n-butyl methacrylate, 2-ethylhexyl acrylate, 2- Ethylhexyl methacrylate, isobutyl acrylate, isobutyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, phenyl acrylate, phenyl methacrylate, benzyl acrylate , benzyl methacrylate, cyclohexyl acrylate, cyclohexyl methacrylate, and the like. Further, in the example of the polyfunctional (meth) acrylate, trimethylolpropane tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, pentaerythritol tri(meth)acrylate, dipentaerythritol Hexa (meth) acrylate, dipentaerythritol penta (meth) acrylate, dipentaerythritol tetra (meth) acrylate, dipentaerythritol tri (meth) acrylate, tripentaerythritol octa (meth) acrylate, tripentaerythritol Hexa (meth) acrylate, tripentaerythritol hexa (meth) acrylate, tripentaerythritol penta (meth) acrylate, tripentaerythritol tetra (meth) acrylate, tripentaerythritol tri (meth) acrylate, and the like.

2) Allyl ester resin material

The allyl ester resin material is a resin material having an allyl group and hardened by radical polymerization. The type of the allyl ester resin material is not particularly limited. In the example of the allyl ester resin material, the bromine-containing (meth) allyl ester resin containing no aromatic ring (refer to JP-A-2003-66201), allyl (meth) acrylate Resin (refer to Japanese Laid-Open Patent Publication No. Hei 5-286896) and allyl ester resin (refer to JP-A Kaiping, Japan) Japanese Laid-Open Patent Publication No. Hei 5-286896, No. 2003-66201, and the like.

3) Vinyl resin material

The type of the vinyl resin material is not particularly limited as long as it can form a transparent resin cured product. The single system of the polyethylene resin is represented by the general formula CH2=CH-R. Examples of the polyethylene-based resin include polyvinyl chloride, polystyrene, and the like. The polyethylene resin is preferably an aromatic vinyl resin containing an aromatic group in R. In particular, a divinyl resin having two or more vinyl groups in one molecule of the monomer is more preferable. These may be used alone or in combination of two or more.

4) epoxy resin material

The type of the epoxy resin material is not particularly limited as long as it has an epoxy group and is light-polymerized or cured by light and heat. As the hardening initiator, an acid anhydride, a cation generating agent, an anion generating agent or the like can be used. Since the epoxy resin has a low curing shrinkage ratio, it is preferable from the viewpoint of improving the molding accuracy.

Examples of the epoxy resin include a novolac phenol epoxy resin, a biphenyl epoxy resin, and a dicyclopentadiene epoxy resin. More specifically, bisphenol F diglycidyl ether, bisphenol A diglycidyl ether, 2,2'-bis(4-glycidyloxycyclohexyl)propane, 3,4-epoxy Cyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, ethylene cyclohexene dioxide, 2-(3,4-epoxycyclohexyl)-5,5-spiro-(3,4- Epoxycyclohexane)-1,3-dioxane, bis(3,4-epoxycyclohexyl) adipate, A polymer such as 1,2-cyclopropanedicarboxylic acid bisglycidyl ester.

5) Photopolymerization initiator

The type of the photopolymerization initiator is basically selected in accordance with the kind of the composition (resin material) to be polymerized. The type of the photopolymerization initiator is not particularly limited as long as it has a maximum absorption at a wavelength in the ultraviolet region (400 nm or less) and generates a radical, a cation or an anion at a wavelength in the ultraviolet region. Further, when the photopolymerization initiator is selected, the light transmittance in the wavelength range of use is lowered in consideration of the value, and it is preferable that the absorbance is appropriate for the hardened light (ultraviolet light).

As the photopolymerization initiator which generates a radical, any of an intramolecular cracking type initiator and a hydrogen absorption reaction type initiator can be used. The intramolecular cracking type initiator has a benzoin ether-derived type, an acetophenone type, a mercaptophosphine oxide type, and the like. Examples of the acetophenone type include a benzyl ketal, an α-hydroxyacetophenone, an α-aminoacetophenone, and the like. Examples of the mercaptophosphine oxide type include bis-decylphosphine oxide (BAPO), monodecylphosphine oxide (MAPO), and the like. The hydrogen extraction reaction type initiator has a diphenyl ketone type, an amine type, a thioxanthone type, and the like.

Here, in consideration of the case where the resin is not yellowed in order to be used in the lens portion, the α-hydroxyacetophenone is DAROCURE 1173, IRGACURE 184, IRGACURE 127 (all are Ciba. Japan Co., Ltd.), and the like. It is better. Further, the α-aminoacetophenone is preferably IRGACURE 907 or IRGACURE 369 (all are Ciba. Japan Co., Ltd.).

Further, a photopolymerization initiator which generates a radical is also preferably a photopolymerization initiator which has an effect of performing photobleaching after UV irradiation. Examples of such photopolymerization initiators include mercaptophosphine oxides and the like. When a photopolymerization initiator having a photofading effect is used, the absorption band of the photopolymerization initiator disappears (light fading) accompanying the photoreaction, whereby the hardened light reaches the deeper portion of the resin to promote internal hardening of the resin. . In the case of the mercaptophosphine oxide, 2,4,6-trimethylbenzimidyl-diphenyl-phosphine oxide (DAROCUR TPO) of MAPO, or double of BAPO (2,4,6) -Trimethylbenzhydryl)-phenylphosphine oxide (IRGACURE 819), or IRGACURE 784 of a titanocene compound (all are Ciba. Japan Co., Ltd.) and the like. In particular, DAROCUR TPO or IRGACURE 819 is colorless due to photoreaction, and therefore is more preferable as a lens.

The photopolymerization initiator which produces a cation has an onium salt, a phosphonium salt, a diazonium salt, a ferrocene salt or the like. Examples of the yttrium salt include: CYRACURE UVI-6976, UVI-6992 (all are Dow Chemical), SUN-aid SI-60L, SI-80L (Sanshin Chemical Industry Co., Ltd.), ADEKA OPTOMER SP-150 , SP-170 (company ADEKA), Uvacure 1590 (DAICEL UCB Co., Ltd.), etc. Examples of the sulfonium salt include UV9380C (Momentive Performance Materials Japan Co., Ltd.), IRGACURE 250 (Ciba. Japan Co., Ltd.), and the like.

The photopolymerization initiator which produces an anion has an alkyllithium, a carbamate derivative, an oxime ester derivative, a photoamine generator, and the like.

The amount of the photopolymerization initiator to be added is preferably in the range of 0.001% by mass to 5% by mass, more preferably 0.01% by mass to 3% by mass based on the photocurable resin material (resin material and photopolymerization initiator). Within the range of %, particularly preferably in the range of 0.05% by mass to 1% by mass.

6) Thermal polymerization initiator

The thermal polymerization initiator may, for example, be diisopropylbenzene hydroperoxide, 1,1,3,3-tetramethylbutyl hydroperoxide, cumene hydroperoxide or tert-hexyl hydrogen. Hydroperoxides such as peroxides, tert-butyl hydroperoxides, α,α'-bis(tert-butylperoxy-m-isopropyl)benzene, (cumyl) peroxide, 2,5-dimethyl-2,5-bis(tert-butylperoxy)hexane, tert-butyl a dialkyl peroxide such as a base peroxide, a di-tert-butyl peroxide or a 2,5-dimethyl-2,5-bis(tert-butylperoxy)hexane-3 An organic peroxide such as a ketone peroxide, a peroxyketal, a dimercapto peroxide, a peroxydicarbonate or a peroxyester, or 2,2'-azobisisobutyl Nitrile, 1,1'-(cyclohexane-1-carbonitrile), 2,2'-azobis(2-cyclopropylpropionitrile), 2,2'-azobis(2,4-dimethyl An azo compound or the like such as valeronitrile.

The thermal cationic hardener may, for example, be an ammonium salt having at least one alkyl group, a phosphonium salt, a phosphonium salt, a diazonium salt or a boron trifluoride. Triethylamine complex and the like. Examples of the counter anion of these salts include, for example, SbF ₆ ^- , PF ₆ ^- , AsF ₆ ^- , BF ₄ ^- , decyl (pentafluoro) borate, trifluoromethanesulfonate, methanesulfonate, trifluoro Anions such as acetates, acetates, sulfonates, tosylates, nitrates, and the like.

<Modified Polyoxane>

In the polyoxymethylene, the organic group is introduced into the side chain and the terminal is referred to as a modified polyfluorene oxygen, and is roughly classified into four types of structures by the bonding positions of the substituted organic groups. In addition, it is classified into reactive polyfluorene and non-reactive polyoxane by the nature of the introduced organic group. For example, epoxy modified polyoxymethylene refers to a group in which a part of a methyl group of polyoxymethylene is substituted with an alkyl group containing an epoxy group. Here, modified polyoxane having a functional group which chemically reacts with a functional group of an energy-curable resin to form a bond is used. For example, in the case of an epoxy resin, an epoxy-modified polyfluorene oxide, a polyester-modified polyfluorene oxide, an amine-modified polyfluorene oxide, or the like can be used. In the case of an acrylic resin, methacrylic acid modified polyfluorene oxide or carboxyl modified polyoxyl oxide can be used.

Preferable examples of the polyoxymethylene compound include a plurality of dimethyl decyloxy units as a repeating unit and a substituent at the terminal and/or side chains of the compound chain. A structural unit other than dimethyl nonyloxy group may be contained in the compound chain containing a dimethyl nonyloxy group as a repeating unit. The substituent groups may be the same or different, and a plurality of substituents are preferred. Examples of preferred substituents include polyether groups, alkyl groups, aryl groups, aryloxy groups, acryl groups, methacryl groups, vinyl groups, aryl groups, cinnamyl groups, epoxy groups, and epoxy groups. a group of a propane group, a hydroxyl group, a fluoroalkyl group, a polyoxyalkylene group, a carboxyl group, an amine group or the like.

The number average molecular weight of the modified polyoxane is set to 1000 or more and 50,000 or less, but more preferably from 1,000 to 30,000, more preferably from 1,000 to 20,000, still more preferably from 2,000 to 20,000. Here, the quantity is flat The measurement of the average molecular weight (Mn) was carried out by gel permeation chromatography (GPC) using tetrahydrofuran as a developing solvent, and the value was determined in terms of polystyrene. In the present specification, the GPC measuring device HLC-8020 (manufactured by TOSOH Co., Ltd.) and the GPC column (passed in the following order) are used: TSK guard column HXL-H, TSK gel GMHXL (×2), TSK gel G2000HXL ( The above is a value measured by the condition that the measurement solvent is tetrahydrofuran and the temperature is 40 ° C. When the number average molecular weight of the modified polyfluorene is too small, when added to the energy curable resin composition, the softness of the energy curable resin obtained after the curing is insufficient, and it is easy to generate chips at the time of cutting. . Further, when the number average molecular weight of the modified polyfluorene is too small, the addition of the energy curable resin composition may impair the flexibility of the finally obtained hardened energy curable resin, or may cause the original resin composition. The problem of adjustment or processing becomes difficult. Therefore, in the present invention, the above problem is less likely to occur, and from the viewpoint of being easily obtainable, the modified polyfluorene oxide having the number average molecular weight in the above numerical range is used.

The content of the polyfluorene oxygen atom of the polyoxymethylene compound is not particularly limited, but is preferably 0.5 to 10% by mass based on the total amount of the energy curable resin composition.

Examples of preferred polyoxo-oxygen compounds include "X-22-174DX", "X-22-2426", "X-22-164B", and "X22-164C" manufactured by Shin-Etsu Chemical Co., Ltd. "X-22-170DX", "X-22-176D", "X-22-1821" (above is the trade name); "FM-0725", "FM-7725", "CHISSO" FM- 4421", "FM-5521", "FM-6621", "FM-1121" (above is the trade name); "DMS-U22", "RMS-033", "RMS-083", "UMS" by Gelest -182", "DMS-H21", "DMS-H31", "HMS-301", "FMS121", "FMS123", "FMS131", "FMS141", "FMS221" (above); Dow Corning "SH200", "DC11PA", "SH28PA", "ST80PA", "ST86PA", "ST97PA", "SH550", "SH710", "L7604", "FZ-2105", "FZ2123" manufactured by Toray Co., Ltd. ", FZ2162", "FZ-2191", "FZ2203", "FZ-2207", "FZ-3704", "FZ-3736", "FZ-3501", "FZ-3789", "L-77" ", L-720", "L-7001", "L-7002", "L-7604", "Y-7006", "SS-2801", "SS-2802", "SS-2803", "SS-2804" and "SS-2805" (the above are trade names); "TSF400", "TSF401", "TSF410", "TSF433", "TSF4450", "TSF4460" manufactured by Momentive Performance Materials Japan (above The product name) is not limited to this.

According to the present invention, it is possible to provide a lens array capable of mass-producing an optical element at a low cost, a method of manufacturing a lens array, and a method of manufacturing an optical element.

10‧‧‧Auxiliary light source unit

11‧‧‧Substrate

12‧‧‧Light source

13‧‧‧Optical components

13B‧‧‧Lens Department

13C‧‧‧ datum

13V‧‧‧V groove, valley

13a‧‧‧parallel plate

13b‧‧‧Light penetration

13c‧‧‧ wheel belt

13cx‧‧‧ sector

13cy‧‧‧ sector

14‧‧‧ spacers

14a‧‧‧ inner circumference

50‧‧‧ camera device

60‧‧‧ operation button

100‧‧‧Mobile phone

BK‧‧‧ bottom plate

C‧‧‧cutting knife

HB‧‧‧ solder balls

IM‧‧‧formed body

LA‧‧‧Lens Array

M‧‧‧Mold

Ma‧‧·Transfer surface

Mb‧‧‧ Uplift

OPx‧‧‧ optical axis outer side

OPy‧‧‧ outside of the optical axis

PL‧‧‧Resin

M1, M1’, M1”

M2‧‧‧ opposite mode

M1a‧‧‧Lens Transfer Department

M1b‧‧‧ convex transfer part

[Fig. 1] is a perspective view of an auxiliary light source unit 10 of an optical element manufactured by the manufacturing method of the first embodiment.

[Fig. 2] A view of the auxiliary light source unit 10 viewed from the exit surface side.

[Fig. 3] A view in which the structure of Fig. 2 is cut along the line III-III and viewed in the direction of the arrow.

[Fig. 4] is a perspective perspective view of the auxiliary light source unit 10.

[Fig. 5] is an external view of a mobile phone 100 as an example of a mobile terminal provided adjacent to the auxiliary light source unit 10 and the imaging device 50, wherein (a) is a surface and (b) is a back surface.

[Fig. 6] is a view showing manufacturing steps (a) to (h) of the auxiliary light source unit.

[Fig. 7] is a view showing a state in which the cutting blade is elastically supported, and (a) shows that the leading end of the cutting blade C is guided to an appropriate cutting position, and (b) shows the cutting blade C. The front end is guided to the appropriate cut position.

[Fig. 8] is a view showing an example in which the base layer is one layer, and (a) is a view showing the lens portion 13B formed directly on the bottom plate BK, and (b) is a view showing the auxiliary light source unit having the lens portion 13B. .

[Fig. 9] is a perspective view showing an example of a lens array sheet.

Fig. 10 is a perspective view showing another example of the lens array sheet.

[Fig. 11] Although a perspective view showing another example of the lens array sheet is shown, the valley portion is omitted.

[Fig. 12] shows a lens array thin film having a lens portion according to a modification Top view of the piece.

Fig. 13 is a cross-sectional view showing a mold used for molding a lens array in the second embodiment.

[Fig. 14] is a view showing manufacturing steps (a) to (g) of the lens array.

[Fig. 15] (a) is a view showing a step of assembling the auxiliary light source unit, and (b) is a cross-sectional view of the auxiliary light source unit.

[Fig. 16] (a) is a view showing a part of a mold M1' of a modification and a part of a lens array LA formed thereby, and (b) is a cross-sectional view of an auxiliary light source unit according to a modification.

[Fig. 17] (a) is a perspective view of a lens array in which an unnecessary portion is formed, (b) is a view in which the structure is cut in the direction of the arrow by the XB-XB line (a), and (c) is not A perspective view of the lens array after the partial division is required.

[Fig. 18] Fig. 18 is a view showing manufacturing steps (a) to (e) of the lens array of another embodiment.

[Fig. 19] is a perspective view showing a state in which the lens portions arranged in one row are peeled off.

[Fig. 20] A perspective view of a lens array according to a modification.

[21] Fig. 21 is a cross-sectional view of a lens array according to a modification.

Hereinafter, embodiments of the present invention will be described with reference to the attached drawings. In addition, the dimensional ratio of the schema is for convenience of explanation. More exaggerated, there will be a difference between the actual ratio.

<First embodiment>

Fig. 1 is a perspective view of an auxiliary light source unit 10 of an optical element manufactured by the manufacturing method of the present embodiment. Fig. 2 is a view of the auxiliary light source unit 10 shown in Fig. 1 viewed from the exit surface side. Fig. 3 is a view in which the structure of Fig. 2 is cut along the line III-III and viewed in the direction of the arrow. Fig. 4 is a perspective perspective view of the auxiliary light source unit 10 shown in Fig. 1. Further, the optical axis direction of the optical element is set to the Z direction, the direction perpendicular to the Z direction is referred to as the X direction, and the direction perpendicular to the Z direction and the X direction is referred to as the Y direction.

As shown in FIG. 2 and FIG. 3, the auxiliary light source unit 10 of the present embodiment is an LED light source 12 that is mounted on the surface of the rectangular substrate 11 and is a light-emitting element, and is provided on the light-emitting side of the LED light source 12. The optical element 13 having a rectangular outer shape and a spacer 14 disposed between the LED light source 12 and the optical element 13 as a holding member are formed. The spacer 14 has a rectangular outer shape and a cylindrical inner shape as shown in Fig. 4, and its lower end is fixed to the upper surface of the substrate 11 by an adhesive, and its upper end is fixed to the optical element 13 by an adhesive. below. The inner circumferential surface 14a of the spacer 14 is a diffusion surface (white coating surface).

The substrate 11 is roughly constituted by a substrate main body, an insulating layer, and a wiring pattern. The main substrate of the substrate is made of aluminum. The insulating layer is laminated on the substrate main body, and the wiring pattern is formed on the insulating layer. A conductor made of Cu or the like. Connected to the wiring pattern to form the LED light source 12 LED chip.

The LED light source 12 as an auxiliary light source is configured such that the LED wafer is completely covered by a phosphor-containing transparent resin body (translucent resin containing a phosphor) formed by a rectangular flat mold, and is emitted from the LED wafer. Light passes through the transparent resin body containing the phosphor. With this configuration, for example, a blue light-emitting diode is used as the LED wafer, and a yellow phosphor is used as the phosphor contained in the phosphor-containing transparent resin, whereby white light can be emitted. Further, the LED chip preferably has a rectangular shape with sides in the X direction and the Y direction.

The optical element 13 is formed on a parallel flat plate 13a (light emitting side), and forms a circular planar (or spherical or aspherical) light transmitting portion 13b and a surrounding light transmitting portion 13b provided at the center portion. The surrounding lightning-type belt portion 13c is formed. A slope of a V-groove 13V, which will be described later, is formed around the belt portion 13c. The optical axis of the optical element 13 is passed through the center of the light transmitting portion 13b. The manufacturing method of the optical element 13 will be described later.

As shown in Fig. 2, the belt portion 13c is divided into four in the circumferential direction, and has a pair of first (13) portions of the fan portion 13cx that are opposed to each other in the X direction. The penetrating portion 13b faces in the Y direction and is wrapped around the pair of fan portions 13cy of the pair of the fan portions 13cx. The sectors 13cx and 13cy are in contact with each other. As shown in Fig. 3, the pair of fan portions 13cx have a plurality of first partial belt RPx including an optical axis side surface IPx and an optical axis outer side surface OPx around the optical axis, and the pair of fan portions 13cy are lighted. The axis is centered and has an optical axis side IPy and The second partial portion of the optical axis outer side OPy is RPy. In the present embodiment, the height d1 of the first partial belt RPx is equal to the height d2 of the second partial belt RPy.

Further, in the third drawing, the fan portions 13cx and 13cy are displayed to face each other for convenience of illustration, but actually, the fan portions 13cx and 13cy are not opposed to each other. Further, on the light emitting side of the optical element 13, an identification code (not shown) is formed to recognize the (first) pair of the sector 13cx and the (second) pair of sectors 13cy. The identification symbol is used to indicate the direction of the belt portion when the auxiliary light source unit is incorporated into the machine together with the image pickup device (in this example, a certain direction of the pair of sectors 13cy), and can be incorporated when being incorporated. Confirm the X direction and the Y direction to prevent the group from entering the wrong direction. In addition, the first resin layer in the underlying layer composed of two layers, which will be described later, may be formed as a parallel flat plate 13a, and the portion corresponding to the parallel flat plate 13a may be integrally formed with the lens portion.

(a) and (b) of FIG. 5 are external views of a mobile phone 100 as an example of a mobile terminal provided with the auxiliary light source unit 10 of the present embodiment adjacent to the imaging device 50. The mobile phone 100 shown in FIG. 5 is connected to the outer casing upper body 71 and the lower casing 72 via a hinge 73. The upper casing 71 includes display screens D1 and D2, and the lower casing 72 is provided as a lower casing 72. The operation button 60 of the input unit. The imaging device 50 and the auxiliary light element unit 10 are built in the lower side of the display screen D2 in the upper housing 71, and the auxiliary light source unit 10 emits light reflected from the outer surface side of the upper housing 71 to reflect the subject. It is configured to enter the imaging device 50. In addition, the position of the imaging device may be disposed on the display screen D2 in the upper housing 71. Top or side. Further, the mobile phone is of course not limited to folding. In addition, the mobile phone system includes a smart phone or the like.

When the auxiliary light source unit 10 of the present embodiment is mounted on the mobile phone 100, the X direction is the short side direction (vertical direction) of the imaging element, and the Y direction is the longitudinal direction (horizontal direction) of the imaging element. When the imaging of the subject is performed using the imaging device 50, the auxiliary light source unit 10 emits light. At this time, the light that is emitted from the LED light source and passes through the light transmitting portion 13b of the optical element 13 travels directly when the light transmitting portion 13b is a flat surface, and travels when the curved surface is refracted.

On the other hand, among the light rays that have entered the optical element 13 and passed through the parallel flat plate 13a, the light rays incident on the pair of fan portions 13cx are refracted toward the optical axis outer side surface OPx of the first partial wheel RPx, and are then emitted toward the subject. Further, among the light rays that have entered the optical element 13 and passed through the parallel flat plate 13a, the light rays incident on the pair of fan portions 13cy are refracted toward the optical axis outer side surface OPy of the second partial wheel RPy, and are then emitted toward the subject. Irradiation with the imaging screen can be performed by the light emitted from the auxiliary light source unit 10.

(Example of the first manufacturing step)

Next, a manufacturing procedure of the auxiliary light source unit will be described with reference to Fig. 6 . The cutting blade device CA used in the present embodiment has a plurality of cutting blades C as shown in Fig. 7(a), and is elastically supported from both sides by a spring mechanism SP, so that it can be fixed in the pair. In the absence of illustration The direction in which the molded body IM of the jig is inserted (the vertical direction in Fig. 7(a)) moves in a direction intersecting.

As shown in Fig. 6(a), the transfer surface of the mold M includes a first portion corresponding to the plurality of lens portions 13B and a second portion surrounding the convex portion surrounding the first portion. In other words, the mold M is provided with a resin PL (here, an ultraviolet curable epoxy resin) covering the transfer surface Ma and the raised portion Mb, and the mold M has light passing through the lens portion 13B constituting the optical element 13. The translucent portion 13b and the belt portion 13c correspond to the plurality of transfer surfaces Ma and the wedge-shaped raised portions Mb disposed between the transfer surfaces Ma.

The surface of the large parallel flat plate 13a (the first resin layer of the base layer: made of polyimine) which is attached to the bottom plate (the second resin layer of the base layer) BK by an adhesive or the like in parallel with this is borrowed. The activation treatment is carried out by ultraviolet light irradiation and thus ozone gas, oxygen plasma or ion etching generated by ultraviolet irradiation.

Then, as shown in Fig. 6(b), the activated surface of the parallel flat plate 13a is placed on the resin PL applied to the mold M, and ultraviolet rays are irradiated from the outside in this state. The resin PL is hardened and integrated with the parallel flat plate 13a. Then, the formed body IM is integrally released from the mold M.

The mold release molded body IM is attached to the parallel flat plate 13a of the bottom plate BK formed of any one of a polyimide resin, a TAC, a PET, an acrylic resin, and an epoxy resin, and is disposed at a specific interval. There are a plurality of lens portions 13B (lens layers), and further, between the lens portions 13B, A plurality of V-shaped valley portions (V grooves) 13V corresponding to the ridge portion Mb are formed. The angle of the 13V of the valley is preferably 30~60°. Therefore, as shown in Fig. 6 (c) and (d), the plurality of cutting blades C having the pitch and the valley portion 13V are opposed to each other and strongly moved relative to each other. The cutting blade C is integrally held by the cutting blade device CA as shown in Fig. 7 (a) and (b), and is elastically supported by the spring mechanism SP. Therefore, the front end of the cutting blade C can be borrowed. It is free to move when guided by the trough 13V to an appropriate cutting position. Further, the cutting edge angle θ of the cutting blade C is 20 to 55°, and if the groove angle of the valley portion 13V is smaller than 5°, it is easy to insert into the V groove, and even if the cutting blade has a front end position, It is preferable that the cutting blade is guided to the V-groove wall surface and guided to the cutting position. Further, the durability of the blade can be ensured by setting the tip end angle of the cutting blade to 20° or more.

Although the leading end of the cutting blade C enters the parallel flat plate 13a, it passes through this and reaches the bottom plate BK, but stops (or partially penetrates) in the middle of the bottom plate BK. In the above-described manner, a resin lens layer having a plurality of lens portions and a resin base layer bonded to the lens layer are formed, and a cut portion is formed around the lens layer in the lens layer, and the cut portion is reached. The base layer, but does not penetrate the lens array sheet of the base layer. As described above, as long as the tip end of the cutting blade C is stopped in the middle of the bottom plate BK, as shown in Fig. 6(e), the cutting portion SL is generated at the bottom of the valley portion 13V after the cutting blade C is retracted. However, the cut parallel flat plate 13a can be fixed only by the adhesive force with the bottom plate BK, and is not easily peeled off during transportation, and is therefore excellent in handleability.

On the other hand, after the assembly step of being transferred to the auxiliary light source unit, as shown in FIG. 6(f), since the cut portion SL is provided at the bottom of the valley portion 13V, it is easy to separately follow the cut portion SL. The parallel flat plate 13a is peeled off from the bottom plate BK together with the lens portion 13B, and as shown in Fig. 6(g), the auxiliary light source unit 10 is completed by being fixed to the substrate 11 on which the spacer 14 and the LED light source 12 are attached. The auxiliary light source unit 10 is attached to the back surface of the substrate 11 as shown in Fig. 6(h), and is transferred to a reflow step (not shown) to be attached to a mobile terminal or the like.

In the above embodiment, an example in which the underlayer is formed in two layers is shown, but the underlayer may be only one layer. Specifically, as shown in Fig. 8(a), the lens portion 13B as a lens layer can be directly formed on the bottom plate BK as the base layer. At this time, the cutting blade penetrates the lens layer but stops in the middle of the base layer. The lens portion 13B is peeled off from the bottom plate BK, and is directly attached to the spacer 14 as shown in Fig. 8(b) to be an auxiliary light source unit.

Further, the lens array sheet may be formed such that the lens portions 13B are arranged in a line. In the ninth aspect, the lens array sheet in which the above-described cut-in portion is formed from the molded body IM formed in one row is displayed, and the aligned lens portion 13B is peeled off from the end portion by the robot RB and transferred to the assembly step.

On the other hand, the lens array sheet may be formed such that the lens portions 13B are arranged in a matrix. Fig. 10 is a perspective view showing a molded body IM in which the lens portions 13B are formed in a matrix. As mentioned above, make In the case where the molded body IM in which the lens portions 13B are arranged in a matrix is incorporated in the cut-in portion SL, as shown in Fig. 10, a cutting device in which the cutting blades C are arranged in a lattice shape may be used. The cutting portion SL can be simultaneously formed by the cutting blade C of the longitudinal and lateral directions simultaneously invading the valley portion 13V between the lens portions 13B.

Further, as shown in Fig. 11, the lens portion 13B may be arranged in a plurality of rows on the bottom plate BK, and the lens portions 13B of the adjacent rows may be shifted in the column direction. Thereby, the lens portion 13B can be formed in an approximately circular state, which is preferable because it is easy to handle.

Further, as shown in Fig. 12(a), the outer shape of the lens portion 13B may be circular. At this time, the lens portion 13B can be taken out from the bottom plate BK by protruding the back side of the lens portion 13B with a pin. Alternatively, as shown in Fig. 12(b), the lens portion 13B may have a rectangular outer shape, and may have a polygonal shape as shown in Fig. 12(c). In either case, the valley portion 13V is provided so that the lens portion 13B is curled, and the cut portion is formed by the cutting blade C corresponding to the valley portion 13V to form the lens array sheet.

As described above, the V-shaped valley portion (V-groove) 13V formed to surround the periphery of the lens portion 13B in the lens layer constitutes a concave portion. The base layer has, for example, two layers of the parallel flat plate 13a and the bottom plate BK, and is bonded to the lens layer so that the parallel flat plate 13a can be peeled off from the bottom plate BK. For example, the bottom plate BK is detachably joined to the lens layer as a sheet. Further, a lens array to which an adhesive sheet is attached is sometimes referred to as a lens array sheet (or a lens sheet).

<Second embodiment>

The auxiliary light source unit 10 of the present embodiment has the same structure as that shown in Figs. 1 to 4, and can be adjacent to the imaging device 50 in the mobile phone 100 as in the fifth (a) and (b). Set up and have the same functionality. The optical element 13 of the auxiliary light source unit 10 can be fabricated from a lens array in the manner described below.

(Example of the first manufacturing step)

The manufacturing steps of the lens array will be described with reference to the drawings. The mold used in the present embodiment is shown in Fig. 13. Further, the number of the lens portions is not arbitrary with respect to the drawings. In Fig. 13, a mold M1 is attached thereto, and has a plurality of lens transfer portions M1a (first portion) and a wedge-shaped convex transfer portion M1b (second portion) as a transfer surface, and the plurality of lens transfer The portion M1a and the light transmitting portion 13b of the optical element 13 correspond to the belt portion 13c (hereinafter referred to as a lens portion 13B); the wedge-shaped convex portion M1b is formed between the lens transfer portions M1a. The angle θ of the convex transfer portion M1b is 20° to 60°.

Since the lens transfer portion M1a and the convex transfer portion M1b are formed by one-time nip processing, the distance between the center of the lens transfer portion M1a and the longitudinal direction of the front end of the convex transfer portion M1b is a. It is formed with excellent precision and equal. In the case where the raw material of the mold is made of metal or the like, the material of the mold is fixed to the jig of the processing apparatus, and the cutting process is performed (there are also different cutting tools). The raw material of the mold is a resin or the like and is formed when the master mold is transferred. It means that the cutting process is performed in a state in which the raw material of the master mold is fixed to the jig of the processing apparatus. The height of the convex transfer portion M1b is higher than the height of the belt forming portion of the lens transfer portion M1a (corresponding to the height d1 of the first partial belt RPx and the height d2 of the second partial belt RPy).

Next, a manufacturing procedure of the lens array will be described with reference to Fig. 14. First, as shown in Fig. 14 (a), the mold M1 having the lens transfer portion M1a and the convex transfer portion M1b is coated with the lens transfer portion M1a and the convex transfer portion M1b. The hardened energy curable resin PL (herein, an uncured ultraviolet curable epoxy resin is used).

Next, as shown in Fig. 14(b), the lower surface of the opposing mold M2 which is a transparent parallel flat plate is placed on the uncured resin PL which is applied to the mold M1, and ultraviolet rays are irradiated from the outside in this state. In order to harden the uncured resin PL. Thereby, the lens array LA made of a curable resin is molded. Further, although the uncured resin may be applied to the flat opposing mold M2, it is more surely prevented from generating bubbles in the lens array LA after molding, as shown in Fig. 14(a). It is preferable to impart an uncured resin to the mold M1 having the lens transfer portion M1a and the convex transfer portion M1b. Further, the light irradiation for curing the resin may be performed from the transparent opposite mold M2 side, but when the mold M1 is transparent, light irradiation from the mold M1 side may be performed, or the mold M1 and the opposite mold M2 may be used. Both of them are illuminated by light. In the case of the thermosetting resin, it is only necessary to cure by heating at a suitable curing temperature. Thereafter, although the lens array LA is demolded, the demold pattern has the following pattern (i) ~(iii), each of the advantages will be explained together.

(i) First, the mold M2 is released from the mold, and then the mold M1 is released.

Since the opposing mold M2 is present in the direction of the gravitational acceleration after the forming, it is easy to work if it is first released from the opposing mold M2.

(ii) First demolding from the mold M1, followed by demolding the opposing mold M2.

Since the mold M1 having the lens transfer portion M1a is difficult to release, the lens array LA is easily broken at the time of demolding. Therefore, by releasing the mold M1 in a state in which the opposite mode M2 is attached to the lens array LA, the lens array LA can be suppressed from being broken. Further, since the mold release M2 is easily released, the problem that the lens array LA is broken at the time of demolding is low.

(iii) Simultaneously demolding the mold M1 and the opposite mold M2.

This can reduce the step time.

As shown in Fig. 14 (c), the mold release lens array LA is formed between the lens portions 13B transferred by the lens transfer portion M1a, and a plurality of corresponding portions corresponding to the convex transfer portion M1b are formed. The valley of the V-shaped section (V-groove) is 13V. The reference surface 13C to be described later is formed on the inclined surface of the convex transfer portion M1b. The angle of the 13V of the valley is 20°~60°. Further, the back surface of the lens array LA transferred by the opposing mold M2 is flat. The height d of the lens array LA is 0.1 mm to 0.5 mm, and the innermost thickness h of the V-groove 13V is 20 μm to 150 μm (see Fig. 18(c)). Further, when d is thickened, since the lens array LA is less likely to be deformed and the mold release property is deteriorated, it is preferable to increase the thickness h. Here, the SiO ₂ coating film or the antireflection coating film (for example, an uneven film of 250 μm or less) may be formed on the back surface of the lens array LA by another step.

Then, as shown in FIG. 14(c), the flexible resin sheet PS as an adhesive sheet is attached to the back surface of the lens array LA by, for example, an ultraviolet curing adhesive which is easily peeled off in the subsequent step. For the flexible resin sheet PS, for example, a polyolefin tape UHP-1525M3 (manufactured by Denki Kagaku Co., Ltd.) with a UV-curable adhesive can be used. The ductility of the flexible resin sheet PS is preferably more than 100% and not more than 130%.

As described above, the flexible resin sheet PS is detachably bonded to the lens array LA as a sheet. Thereafter, in the step shown in any one of Figs. 14(d) to (f), the lens array LA is formed into a sheet by imparting strength to the flexible resin sheet PS.

In the example shown in Fig. 14(d), the lens array LA is subjected to bending stress by bending toward the side of the flexible resin sheet PS, and the cut can be caused in the innermost portion of the most fragile V-groove 13V.

In the example shown in Fig. 14(e), the lens array LA is subjected to bending stress by pressing the flexible resin sheet PS from the back of the lens portion 13B, and can be generated at the innermost portion of the most fragile V-groove 13V. Cut off. This is suitable when the outer diameter of the lens portion 13B is a circular shape (see Fig. 12(a)).

In the example shown in Fig. 14(f), the lens array LA is subjected to bending stress by pulling the flexible resin sheet PS on both sides (or on the diagonal line), and the most fragile V-groove 13V is available. Innermost Produce a cut. Further, the outer peripheral unnecessary portion LAb is simultaneously cut with respect to the adjacent lens portion 13B. This is suitable for the case where the outer diameter of the lens array 13B is a polygonal shape (refer to Fig. 12(c)).

In addition, after the specific heat treatment for promoting the hardening of the curable resin is performed on the lens array LA, the flexible resin sheet PS may be attached, or after the flexible resin sheet PS is attached, the specific heat treatment described above may be performed. .

According to the present embodiment, since the V-groove 13V is formed in the lens array LA formed by curing the uncured ultraviolet curable resin PL, the lens array LA can be cut by using the bottom of the V-groove 13V as a starting point. Thereby, it is easy to realize the singulation of the lens 13 at low cost without relying on cutting. When the sheet lens 13 is conveyed in a state of being attached to the flexible resin sheet PS, it is easy to handle without being broken.

Through the above steps, the lens 13 as an optical element shown in Fig. 14(g) is sliced. The lens 13 has a lens portion 13B as an optical surface and a tapered reference surface 13C around the lens portion 13B. The reference surface 13C is formed accurately so as to have a desired positional relationship with the optical axis of the lens portion 13B.

The installation steps of the auxiliary light source unit will be described. As shown in Fig. 15 (a), the adsorption device VD capable of moving in the three-dimensional direction, wherein the empty adsorption portion VDa is connected to the negative pressure pump P, the hollow adsorption portion VDa having the corresponding reference surface 13C tapered surface. By operating the negative pressure pump P, the inside of the adsorption portion VDa becomes a negative pressure, so The adsorption portion VDa contacts the tapered surface reference surface 13C of the lens 13, and the adsorption device VD can adsorb and hold the lens 13.

The 3-dimensional position of the adsorption device VD is precisely controlled. Therefore, as shown in FIG. 15(b), the substrate 11 on which the spacer 14 and the LED light source 12 are mounted is placed at a specific position in advance, whereby the adsorption device VD is positionally controlled so as to be relative to the LED light source 12. The back surface of the lens 13 is placed on the spacer 14 in a state where the optical axes of the lenses 13 are aligned (for example, with respect to the center of the LED light source 12). Then, it is fixed by an adhesive, whereby the auxiliary light source unit 10 is completed. The completed auxiliary light source unit 10 is attached to the back surface of the substrate 11 with solder balls, transferred to a reflow step (not shown), and attached to a mobile terminal or the like.

According to the present embodiment, the lens portion 13B is integrally formed with the reference surface 13C by the convex mirror transfer M1b in the formed lens 13, so that the lens array LA is along the V groove 13V. When the individual lens unit 13 is combined with the LED light source 12 to produce the auxiliary light source unit, the reference position 13C can be used to accurately determine the position of the lens 13 and the LED light source 12. Further, in the present embodiment, the resin constituting the lens array is an ultraviolet curable resin, but it may be any other photocurable resin. Further, it may be another energy curable resin such as a thermosetting resin. In this case, the hardening reaction may be generated by irradiating the uncured resin with energy required for effects such as heat or radiation instead of light. The energy curable resin is excellent in heat resistance or environmental reliability required for the reflow step of mounting the lens portion together with the light source when the auxiliary light source unit is fabricated. In addition, due to hardening Since the shrinkage ratio is low, it is also preferable from the viewpoint of ensuring the accuracy of the optical surface of the lens portion. Further, it also has an advantage of excellent cutting property. It is also possible to use a thermosetting resin as a material of the lens array. The thermosetting resin is relatively inexpensive compared to the energy curable resin, and has a wide variety of types, and has an advantage that it is easy to select a resin suitable for a desired method. When a thermoplastic resin is used, the resin is heated and melted, and supplied to the mold in a fluid state.

Next, a modification of this embodiment will be described. In the same manner as described above, the mold M1' that is upside down is provided with a lens transfer portion M1a (first portion) as a transfer surface and a convex transfer portion M1b around the same (second). Part). The convex transfer portion M1b has a convex portion M1c having a distal end and a parallel portion M1d on the root side composed of two parallel surfaces. The uncured ultraviolet curable resin PL is transferred and formed by the mold M1', and a parallel groove-shaped notch 13D as a reference surface and a small V-groove 13V are formed around the lens portion 13B. In the same order as described in the above embodiment, as shown in Fig. 17(b), the inside of the V-groove 13V (arrow C') is cut, and the lens array is sliced.

In the present invention, the entire groove including the reference surface of the groove and the determined position is used as the concave portion. However, in FIG. 16(a), the V groove 13V, the reference surface 13D, and the reference surface 13D are connected. The entire conical surface constitutes a concave portion.

In the assembly step of the auxiliary light source unit, as shown in FIG. 16(b), the determination position portion corresponding to the notch 13D is prepared. The bracket 15 of 15a is such that the notch 13D is engaged and abuts against the position determining portion 15a, the lens 13 is housed in the bracket 15, and the adhesive B flows between the bracket 15 and the side surface of the lens 13, Fixed by the adhesive B. Thereafter, the lens 11 is mounted together with the carrier 15 on the substrate 11 on which the LED light source 12 is mounted, thereby completing the auxiliary light source unit. Further, since the notch 13D is a parallel surface, it can be mechanically and easily held by a relatively low-cost gripping device such as a grip arm of a robot without using a high-priced gripping device having an adsorption mechanism. cost.

In addition, as shown in Fig. 17 (a), the uncured ultraviolet curable resin may be hardened around the lens array LA at the time of molding, and a large burr-shaped unnecessary portion LAb may be formed. However, as shown in Fig. 17(b), the V-groove 13V transferred by the convex transfer portion M1b is formed around the outermost peripheral lens portion 13B, and therefore, the V-groove 13V is formed. The innermost portion (arrow C') is easily cut, and as shown in Fig. 17(c), the surrounding unnecessary portion LAb can be easily cut away from the lens array LA.

(Example of second manufacturing step)

Next, another example of the manufacturing steps of the lens array will be described with reference to the drawings. The M1" used in this example has the same shape as the mold M1 of the above-described embodiment, but the difference is that the gate M1g is provided. The opposing mold M2 is common. The resin used is energy-hardening resin. In addition, it may be a thermoplastic resin, but it can be cut after curing or after curing.

As shown in Fig. 18(a), after the mold M1" and the opposing mold M2 are released from the mold, the uncured ultraviolet curable resin PL is filled in the inner cavity CV via the gate M1g. Next, as in the 18th. As shown in Fig. 2(b), the uncured ultraviolet curable resin PL in the cavity CV is cured by irradiating ultraviolet rays from the outside. Fig. 18(c) is filled with unhardened in the cavity CV via the gate M1g. The image after the resin PL is supplied.

Further, as shown in FIG. 18(d), the lens array LA is taken out by opening the mold, but the runner portion LAa corresponding to the gate M1g is formed in the lens array LA, and therefore, as shown in FIG. As shown in (e), the runner portion LAa is cut by the cutter CT. Then, the lens can be sliced by the same steps as those after (c) of Fig. 14.

Further, the lens array LA may be formed such that the lens portions 13B are arranged in a line. In the case of the flexible resin sheet PS, the lens 13 which is arranged in a line is peeled off from the end portion one by one, and is assembled and transferred to the step. status. The lens can be cut simultaneously with the step shown in Fig. 19, and the lens 13 can be cut in advance before the step shown in Fig. 19. The lens 13 shown in Fig. 19 is arranged in a line of lens arrays LA with flexible resin sheets PS, and lenses may be arranged in a two-dimensional lens array from lenses as shown in Fig. 17(c). The cut and the flexible resin sheet PS are cut to cut out one column of the lens array.

On the other hand, the lens array LA may be formed such that the lens portions 13B are arranged in a matrix as shown in FIG.

In addition, as shown in Figure 20, it can also be used in flexible resins. The lens portion 13B on the sheet PS is arranged in a plurality of rows so that the lens portions 13B of the adjacent rows are arranged in the column direction. Thereby, since the lens portion 13B can be formed in a substantially circular state, when the uncured resin is supplied to the mold, the circular expansion property can be matched, and the amount of resin to be wasted can be reduced. In addition, it also has the advantage of making it easy to utilize existing manufacturing machines. In addition, the V-groove 13V is simplified and illustrated.

Further, similarly to the above-described Fig. 12(a), the outer shape of the lens portion 13B may be circular. At this time, the lens portion 13B can be cut by protruding the back side of the lens portion 13B in the lens array LA (see FIG. 14(e)). Alternatively, the lens portion 13B may have a rectangular outer shape as in the case of Fig. 12(b), and may have a polygonal shape as in Fig. 12(c) (an example in which a hexagonal shape is closely arranged). When the outer shape of the lens portion 13B in the lens array LA is a rectangle, it may be a cut form of any one of FIGS. 14(d) to (f).

Fig. 21 is a view showing a lens array LA of a modification. In this example, on the back side of the V-groove 13V, another V-groove 13U is provided in the opposite direction. Thereby, it is easy to exhibit the cutting accuracy, the cutting direction is also unconstrained, and the edge has a sharp advantage.

<Third embodiment>

In the present embodiment, the optical element 13 of the auxiliary light source unit 10 shown in Figs. 1 to 4 can be used as described above, and the mold of Fig. 13 can be used as shown in Fig. 14(a). Each step of (g) is carried out in the same manner, but the energy-hardening resin used contains a specific modification. Poly-oxygen.

According to the present embodiment, the flexibility of the modified polyfluorene is imparted by using an energy curable resin containing a specific modified polyfluorene oxide, so that the chip resistance at the time of resin cutting is improved. In addition, by adding a specific modified polyfluorene oxide, the conductivity of the surface of the lens array LA is improved, and the friction is weakened, whereby the static electricity is not easily accumulated in the resin, so that dust adhesion can be alleviated.

(Example)

Hereinafter, embodiments of the invention will be described. The inventors of the present invention prepared the resin composition of the examples and the comparative example 3 by adding the modified polyfluorene oxide described later to the resin material described later, for evaluation as described later. Further, in Comparative Examples 1 and 2, modified polyfluorene oxygen was not added. Hereinafter, the chemical formula of the resin material at the time of addition of the modified polyfluorene oxygen is shown.

The unhardened resin PL is held between the mold M1 of FIG. 18 and the penetrating opposite mold M2, irradiated with UV by the opposite mold M2, or heated in an oven to harden the resin material PL by The mold array is demolded from the mold M1 and the opposite mold M2, and the lens array is formed by a plurality of belt structures having an on-axis thickness of 0.35 mm, a height of 70 μm, and a pitch of 0.1 mm. A lens portion having a circular flat portion of 0.5 mm and a V-groove having an angle of 30° for cutting and a thickness of 50 μm at the bottom of the groove are formed between the lens portions. The formed lens array was attached to a flexible resin sheet, and the sheet was deformed and cut, and the lens was sliced.

(Resin material) [Comparative Examples 1, 3 to 5, and Examples 1 to 7]

. Photocurable epoxy resin composition: an aromatic sulfonium salt as a photopolymerization initiator (CYRACURE UVI-6976; Dow Chemical Co., Ltd.) is added as a photopolymerization initiator to bisphenol A diglycidyl ether in an amount of 0.1% by weight of the entire composition. )By

[Comparative Example 2, Example 8]

. Thermosetting epoxy resin composition: an aromatic sulfonium salt (SUN-aid SI-110L; three as a thermal polymerization initiator) is added to bisphenol A diglycidyl ether in an amount of 0.1% by weight of the entire composition. New Chemical Co., Ltd.)

[Comparative Examples 6, 7, and Examples 9, 11 to 15]

. Photocurable acrylic resin composition: α-hydroxyacetophenone (IRGACURE 907; Ciba.) as a photopolymerization initiator was added to cyclohexyl (meth) acrylate in an amount of 0.1% by weight of the total composition. Japan Co., Ltd.)

[Embodiment 10]

. Thermosetting Acrylic Resin Composition: α,α'-azobisisobutyronitrile (AIBN) as a thermal polymerization initiator added to cyclohexyl (meth) acrylate as 0.1% by weight of the entire composition ; Otsuka Chemical Co., Ltd.)

(starting agent)

[Comparative Examples 1 to 5, Examples 1 to 8]. Aromatic sulfonium salt

[Comparative Examples 6, 7, and Examples 9, 11 to 15]. --hydroxyacetophenone

[Example 10]. α,α'-azobisisobutyronitrile

(Modified polyoxane: the amount added (relative to the ratio of the total weight after the addition of modified polyfluorene) is shown in Table 1) [Comparative Example 3]

. Polyfunctional phenyl: methyl phenyl polyfluorene (KF-54; Shin-Etsu Chemical Co., Ltd., Mn = 2800)

[Examples 1 to 4]

. Monofunctional epoxy group: single-end epoxy modified polyfluorene (X-22-173DX; Shin-Etsu Chemical Co., Ltd., Mn=4600)

[Comparative Example 6, Examples 5 to 8]

. Polyfunctional epoxy group A: side chain two-end type epoxy modified polyfluorene (X-22-9002; Shin-Etsu Chemical Co., Ltd., Mn=7800)

[Comparative Example 4, Examples 9 to 12]

. Monofunctional methacryl group: single-end methacrylic acid modified polyfluorene (X-22-2426; Shin-Etsu Chemical Co., Ltd., Mn=12000)

[Examples 13 to 15]

. Polyfunctional methacryl-based A: two-terminal methacrylic acid modified polyfluorene (X-22-164C; Shin-Etsu Chemical Co., Ltd., Mn=2400)

[Comparative Example 7]

. Polyfunctional methacryl B: two-terminal methacrylic acid modified polyoxo (X-22-164; Shin-Etsu Chemical Co., Ltd., Mn=860)

(hardening condition)

For photocurable epoxy resins, use a mercury lamp at room temperature The intensity of 20 mW was irradiated with ultraviolet rays for 300 seconds to harden it. The thermosetting epoxy resin was cured by heating at 90 ° C for 60 minutes using an atmospheric oven. The photocurable acrylic resin was cured by irradiating ultraviolet rays with a mercury lamp at a strength of 20 mW for 100 seconds at room temperature. The thermosetting acrylic resin was cured by heating at 90 ° C for 30 minutes using an atmospheric oven.

(evaluation method) For "cutting patience":

When the sliced surface of the 81 lenses is observed by a microscope, if the lens having a chip of 200 μm or more does not reach 5% of the total, it is regarded as ◎, and if it is 5% or more and less than 10%, it is regarded as ○. If it is 10% or more and less than 20%, it is regarded as △, and if it is 20% or more, it is regarded as ×.

For "foreign matter attachment":

When the lens surface of the 81 lenses is observed by a microscope, if the lens having a foreign matter of 100 μm or more is less than 5% of the total, it is regarded as ◎, and if it is 5% or more and less than 10%, it is regarded as ○, if 10% If it is less than 20%, it is regarded as △, and if it is 20% or more, it is regarded as ×.

For "bubbles":

When 81 lenses are formed by a microscope, if the lens of 10 or more bubbles per lens does not reach 5% of the total, it is regarded as ◎, and if it is 5% or more and less than 10%, it is regarded as ○. If 10% or more and less than 20 % is regarded as △, and if it is 20% or more, it is regarded as ×.

For "heat resistance":

Among the 81 lenses which were sliced, three were subjected to a heat resistance test (100 ° C for 500 h), and the transmittance before and after the test (measuring system spectrophotometer U-4100; manufactured by Hitachi High-Tech) was measured. Then, if the change in the transmittance of 450 nm before and after the heat resistance test is less than 5%, it is regarded as ◎, and if it is 5% or more and less than 10%, it is regarded as ○, and if it is 10% or more and less than 15%, it is regarded as Δ. More than 15% is regarded as ×.

The summary of the evaluation results is shown in Table 1. According to the evaluation results of Table 1, it is understood that in Comparative Examples 1 and 2, the "heat resistance" is ◎, but the "cutting resistance", "foreign matter adhesion", and "bubble" are practically unsuitable standards, and are not suitable for cutting. Sliced. It can be seen that the functional groups of the modified polyfluorene added in Comparative Examples 3, 4, and 6 are different from the functional groups of the resin, and the "bubble" is ◎, but the "cutting resistance" is a practically unsuitable level and the same. The land is not suitable for the fragmentation caused by the cut. In Comparative Examples 5 and 7, it is presumed that the number average molecular weight of the modified polyfluorene oxide is small, and it is not possible to impart sufficient flexibility to the resin after curing. Although "foreign matter adhesion" and "bubble" are good, "heat resistance" can be Practical but slightly lower, and "cutting tolerance" is a practically unsuitable level.

On the other hand, in Examples 1 to 15 in which the functional group of the modified polyfluorene added was the same as the functional group of the resin, "cutting resistance", "foreign matter adhesion", "bubble", and "heat resistance" were either All of them are evaluations of a practical level of Δ or more, particularly examples in which the content of the modified polyfluorene oxide is in the range of 1.2 to 9.3 wt%, "cutting resistance", "foreign matter adhesion", "bubble", "heat resistance". "Essence" is an evaluation of ○ or more.

The present invention is not limited to the embodiments and examples described in the specification, and the contents of other embodiments and modifications are included in the description of the embodiments, embodiments, or technical concepts described in the specification. . For example, an optical element manufactured in accordance with the present invention may also be an imaging lens.

11‧‧‧Substrate

12‧‧‧Light source

13B‧‧‧Lens Department

13V‧‧‧V groove, valley

13a‧‧‧parallel plate

14‧‧‧ spacers

BK‧‧‧ bottom plate

C‧‧‧cutting knife

HB‧‧‧ solder balls

IM‧‧‧formed body

M‧‧‧Mold

Ma‧‧·Transfer surface

Mb‧‧‧ Uplift

PL‧‧‧Resin

SL‧‧‧cutting department

Claims (28)

A lens array including a lens array of a plurality of lens portions arranged in an array, wherein the plurality of lens portions and a resin lens layer integrally formed with a concave portion surrounding the periphery of each of the lens portions are provided, and The lens layer is detachably bonded to the adhesive sheet, wherein the lens layer is bonded to the adhesive sheet in a state where the concave portion is bounded by the concave portion. The lens array according to claim 1, wherein the concave portion has a groove having a V-shaped cross section at the bottom, and the groove is formed in a severable manner. The lens array according to claim 2, wherein the corner of the V-shaped cross section of the concave portion is 20° to 60°. The lens array according to claim 2, wherein the lens array at the bottom of the trench has a minimum thickness of 20 μm to 150 μm. The lens array according to any one of claims 2 to 4, wherein the concave portion further has a reference surface for determining a position, and the lens portion and the reference surface are integrally molded by a mold. The lens array according to claim 5, wherein the reference plane is formed by a slope of the groove of the V-shaped cross section. The lens array according to claim 5, wherein the reference surface is formed by a notch formed adjacent to the groove. The lens array according to any one of claims 2 to 7, wherein the resin constituting the lens array is an energy curable resin. The lens array according to any one of the invention, wherein the lens layer is composed of an energy curable resin obtained by molding an energy curable resin composition using a mold, the energy hardening The resin composition contains a polymerizable monomer and a modified polyfluorene having a functional group having a bond with a functional group of the polymerizable composition to form a bond, and having a number average molecular weight of 1,000 to 50,000. The lens array according to claim 9, wherein the modified polyanthracene coefficient has an average molecular weight of from 1,000 to 30,000. The lens array according to claim 9 or 10, wherein the content of the modified polyfluorene oxide in the energy curable resin composition is 0.5 to 10% by weight. The lens array according to any one of the preceding claims, wherein the modified polyfluorene-based system has a functional group having two or more functional groups. The lens array according to any one of the invention, wherein the energy curable resin is an ultraviolet curable resin or a thermosetting resin. The lens array according to any one of the invention, wherein the energy curable resin is an epoxy energy curable resin or an acrylic energy curable resin. For example, the lens array described in claim 1 of the patent scope, wherein In the lens layer, a cut portion is formed at a bottom portion of the concave portion, and at least a part of the cut portion reaches the adhesive sheet, but does not penetrate the adhesive sheet. The lens array according to claim 15, wherein the lens layer has a V-groove in the concave portion, the V-groove has an angle of 30° to 60°, and the cut-in portion is formed in the V-groove. bottom of. The lens array according to claim 15 or 16, wherein the resin constituting the lens array is an energy curable resin. The lens array according to any one of the preceding claims, wherein the adhesive sheet has a resin layer between the adhesive sheet and the lens layer, and the cut portion penetrates through the resin layer but does not penetrate the adhesive layer. Sheet. The lens array according to claim 18, wherein a surface of the resin layer opposite to the lens layer is coated with a transparent inorganic layer. The lens array according to any one of the preceding claims, wherein the lens portions are arranged in a line. The lens array according to any one of the preceding claims, wherein the lens portion has a blaze shape in a cross section in the optical axis direction. The lens array according to any one of the preceding claims, wherein the back surface of the lens portion is a flat surface. A method for producing a lens array, which is a method for producing a lens array of a resin lens layer in which a plurality of lens portions arranged in an array are formed, wherein a resin is formed by using a mold having a transfer surface, and then removed from the mold Forming the lens layer, the transfer surface including a first portion corresponding to the plurality of lens portions and a convex second portion surrounding the periphery of the first portion, and bonding the detachable adhesive sheet to the forming The respective lens portions of the lens layer to which the adhesive sheet is bonded are in a state in which they can be separated from each other by the concave portion. The method of manufacturing a lens array according to claim 23, wherein the concave portion having a depth that can be cut is formed by the molding, whereby the respective lens portions of the lens layer to which the adhesive sheet is bonded are formed by the concave portion It is a state that can be separated from each other. The method of manufacturing a lens array according to claim 23, wherein the cutting blade is inserted while being guided by the groove, and at least a portion of the cutting blade is formed, but the cutting sheet is not inserted through the adhesive sheet. In the portion, the respective lens portions of the lens layer are separated from each other by the concave portion. A method of manufacturing an optical element, wherein the lens array according to any one of claims 2 to 14 is cut along the groove, and each of the lens portions is sliced. The method of manufacturing an optical element according to claim 26, wherein the cutting is performed by the adjacent lens portions adjacent to each other The direction of separation is imparted to the aforementioned lens array. A method of producing an optical element, wherein the lens layer is peeled off from the adhesive sheet of the lens array according to any one of claims 15 to 18.