US20020064575A1 - Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article - Google Patents

Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article Download PDF

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Publication number
US20020064575A1
US20020064575A1 US09/995,832 US99583201A US2002064575A1 US 20020064575 A1 US20020064575 A1 US 20020064575A1 US 99583201 A US99583201 A US 99583201A US 2002064575 A1 US2002064575 A1 US 2002064575A1
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Prior art keywords
resin
resin layer
base member
mold
optical element
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Abandoned
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US09/995,832
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English (en)
Inventor
Akiko Miyakawa
Hirofumi Ishiyama
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Nikon Corp
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Nikon Corp
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Assigned to NIKON CORPORATION reassignment NIKON CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ISHIYAMA, HIROFUMI, MIYAKAWA, AKIKO
Publication of US20020064575A1 publication Critical patent/US20020064575A1/en
Priority to US11/175,259 priority Critical patent/US7622181B2/en
Priority to US12/564,680 priority patent/US7931833B2/en
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00Producing optical elements, e.g. lenses or prisms
    • B29D11/00009Production of simple or compound lenses
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24488Differential nonuniformity at margin
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
    • Y10T428/24612Composite web or sheet

Definitions

  • This invention relates to a resin-cemented optical element, a mold used for producing the element, an optical article (or device) having the element, and fabrication process of the element.
  • optical elements are used in various fields. Depending on the purpose for which they are used, it is difficult to materialize required optical characteristics and so forth in some cases in respect of conventional spherical lenses. Accordingly, aspheric lenses are attracting notice.
  • “Aspheric lens” is a generic term for lenses the curvature of which is kept continuously different over the region extending from the lens center toward the periphery.
  • the use of aspheric lenses at some part of optical systems enables considerable reduction of the number of lenses necessary for the correction of aberrations, compared with a case where the optical system is comprised of only spheric lenses. This enables downsizing and weight reduction of the optical system. Also, the use of aspheric lenses enables high-grade correction of aberrations which is difficult for spherical lenses, and hence can bring about an improvement in image quality.
  • Aspheric lenses having such superior characteristics have not necessarily come into wide use. The greatest reason therefor can be said to be a difficulty in working. Conventional aspheric lenses have only be able to be produced by precisely polishing base members made of glass, and have involved the problem of a high processing cost.
  • the resin-cemented optical element is an element in which a resin layer has been cemented to the surface of a base member made of glass or the like.
  • This resin-cemented optical element is produced by a process such as a composite-type aspherical-surface molding process, in which, using a mold (such as a metal mold), a resin composition (inclusive of a resin precursor composition) is poured into a space between a base member and the mold, followed by curing to form on the base member surface a resin layer having any desired shape.
  • a lens produced by this composite-type aspherical-surface molding process may be called a PAG(plastic adhesion glass) lens.
  • the base member may break when the resin cured on the base member is released from the mold. This phenomenon is remarkable especially when the resin layer has a large thickness. Accordingly, it has been impossible in practice to produce any PAG lens having a thick resin layer of 850 ⁇ m or larger in maximum layer thickness.
  • This phenomenon is considered to be caused by the adhesion of the resin layer to the mold.
  • the resin is released from the mold by means of an ejector (ejection member) in such a way that a force acting in the direction where the former is released from the latter is applied to the base member at its part standing uncovered to the periphery of the element.
  • the base member breaks because of the distortion due to a deformation having exceeded the tolerance limit.
  • an object of the present invention is to provide a resin-cemented optical element having a thick resin layer, without causing any break of the base member, and to provide a mold used for producing the element and an optical article having the element.
  • the present invention provides a resin-cemented optical element comprising a base member and a resin layer formed on the surface of the base member, wherein the resin layer is in a thickness of 300 ⁇ m or smaller at least at a part of a peripheral portion (i.e., a region within 1 mm from the peripheral edge face of the resin layer, or a region outside an effective-diameter region), and is in a thickness of 850 ⁇ m or larger at a position which is thickest in the resin layer.
  • the present invention also provides a mold for forming a resin layer of a resin-cemented optical element having a base member and a resin layer formed on the surface of the base member, wherein the mold has, on the outer periphery on the outside of a molding surface, a concavely curved surface which has a curvature larger than the molding surface. It still also provides an optical article having the resin-cemented optical element of the present invention and a fabrication process of the element.
  • FIG. 1 is a cross-sectional view showing an example of the construction of the optical element according to the present invention
  • FIG. 2 is a cross-sectional view of an optical element having a stair
  • FIG. 3 is an illustration showing an angle at which a normal of the base member surface falls with a resin layer tangent plane
  • FIG. 4 is a cross-sectional view showing an example of the construction of the optical element according to the present invention.
  • FIGS. 5A and 5B illustrate the steps of producing an optical element in Example 1
  • FIG. 6 is a graph showing resin thickness in the optical element produced in Example 1;
  • FIG. 7 is a cross-sectional view showing a mold used in Example 2.
  • FIG. 8 is a cross-sectional view showing a peripheral portion of molding surface of the mold used in Example 2.
  • FIGS. 9A to 9 C illustrate the steps of producing a mold used in Example 2.
  • a resin layer 11 has a thickness of 300 ⁇ m or smaller (preferably 100 ⁇ m or smaller) at least at some part of a peripheral portion (i.e., a region within 1 mm from the peripheral edge face of the resin layer 11, or a region outside the effective-diameter region), and has a thickness of 850 ⁇ m or larger (preferably 1 mm or larger) as the maximum value of the thickness of the resin layer 11 .
  • the resin layer 11 may preferably be formed usually in a thickness of at least 20 ⁇ m, without regard to the inside or outside of the peripheral portion.
  • FIG. 1 what is shown in FIG. 1 takes the case of an optical element whose resin layer molding surface is convex, to which, however, the present invention is by no means limited.
  • the resin layer may have the thickness of 300 ⁇ m or smaller at its whole peripheral portion, but may be enough as long as it has the thickness of 300 ⁇ m or smaller at least at some part of the peripheral portion. This is because the resin in the vicinity where a force for peeling is applied at the time of mold release may have layer thickness in this value.
  • the resin present within 1 mm in periphery from the resin layer edge face closest to the part to which a force for mold release is to be applied i.e., the part against which an ejector is to be pressed
  • the resin present within 1 mm in periphery from the resin layer edge face closest to the part to which a force for mold release is to be applied i.e., the part against which an ejector is to be pressed
  • the resin present within 1 mm in periphery from the resin layer edge face closest to the part to which a force for mold release is to be applied i.e., the part against which an ejector is to be pressed
  • the peripheral portion is meant to be a region within 1 mm from the peripheral edge face of the resin layer 11 , or a region outside the effective-diameter region.
  • a region inside the effective-diameter region is meant to be a region through which light rays used in optical designing are transmitted, thus the region outside the effective-diameter region is meant to be a region except for this region.
  • the resin thickness of an element is strictly determined in accordance with the required optical characteristics. However, as long as it is in the region outside the effective-diameter region, it does not affect any optical characteristics of the element. Hence, the layer thickness can appropriately be selected.
  • the resin layer may preferably have layer thickness which becomes gradually smaller toward the periphery, at least at some part of the peripheral portion.
  • Making the resin layer have such a thickness that does not form any stair so as not to have any abrupt change in thickness is preferred because not only molds can be produced with easy but also any defects can be prevented that may occur because the resin can not turn around when a resin composition is poured into the mold.
  • the resin layer 11 has a maximum layer thickness 12 which is at least four times a minimum layer thickness 13 .
  • the resin layer 11 has a total mass of 700 mg or larger.
  • the resin layer 11 has an external diameter of 34 mm or larger.
  • the base member 10 has a thickness of 10 mm or larger as maximum value.
  • the base member 10 has a thickness of 1 mm or smaller as minimum value.
  • the base member 10 has an external diameter of 35 mm or larger.
  • the base member 10 has a resin layer 11 molding surface which is a concave surface, and the base member 10 has along its periphery a stair 16 which protrudes in the peripheral direction (e.g., an attachment part for fastening the base member to a lens barrel).
  • a stair 16 which protrudes in the peripheral direction (e.g., an attachment part for fastening the base member to a lens barrel).
  • hatching is omitted in FIG. 2 in order to make the illustration easy to view.
  • an angle at which a normal 21 of the interface 20 between the base member 10 and the resin layer 11 falls with a tangent plane 22 on the outside of the resin layer is 80° or smaller as minimum value.
  • the base member 10 has a resin layer 11 molding surface which is a concave surface, and the resin layer 11 has an external diameter 14 which is at least 1.2 times a curvature radius 31 of the concave surface.
  • the base member 10 has a resin layer 11 molding surface which is a concave surface, and the resin layer 11 molding surface has a curvature radius 31 of 24 mm or smaller.
  • the base member has a resin layer molding surface which is a convex surface, and the resin layer has an external diameter which is at least 1.2 times a curvature radius of the convex surface.
  • a resin-cemented optical element having a resin layer with a large maximum layer thickness can be obtained in a good yield.
  • the base member used in the optical element of the present invention there are no particular limitations on the base member used in the optical element of the present invention.
  • Sol-gel glass, inorganic glass and organic glass may be used.
  • an opaque material or a semitransparent material may be used as the base member where the resin is not cured by exposure or, even when cured by exposure the resin can be exposed to light on the side of the mold.
  • Components constituting the inorganic glass may include, e.g., SiO 2 , B 2 O 3 , P 2 O 5 , Na 2 O, K 2 O, CaO, BaO, MgO, ZnO, PbO, MnO, Al 2 O 3 and Fe 2 O 3 .
  • the organic glass may include poly(methyl methacrylate), polystyrene, poly(vinyl chloride), polyester, celluloid, and cellulose derivatives.
  • thermosetting resins which are suited for the present invention, may include, e.g., epoxy resins, urethane resins, thiourethane resins, unsaturated polyester resins, diallyl phthalate resins, and diethylene glycol bisallyl carbonate known under a trade name CR-39.
  • thermoplastic resins may include poly(methyl methacrylate), polystyrene and polycarbonate. Photosensitive acrylic resins and photosensitive methacrylic resins are also preferable for the present invention.
  • a resin composition used in the optical element of the present invention may preferably have a viscosity before polymerization curing, of 50,000 cP or lower at room temperature. If it has a viscosity higher than 50,000 cP, a poor operability may result and besides some failure due to inclusion of bubbles may greatly occur.
  • the resin composition used in the present invention may appropriately optionally contain, in addition to the resin (or a precursor thereof), a polymerizing agent (curing agent), a polymerization initiator, a release agent, an anti-scratching agent and so forth.
  • the polymerizing agent and the polymerization initiator may appropriately be selected depending on the type of and curing conditions for the resin to be used, required film properties and so forth.
  • the releasing agent usable are, e.g., neutralizable or non-neutralizable phosphate alcohols.
  • the anti-scratching agent has the effect of smoothing the surfaces of cured products to improve resistance to scratching, and keeping any faults from occurring.
  • This anti-scratching agent may include silicon oxides such as tetramethoxysilane, tetraethoxysilane, ⁇ -methacryloxypropyltrimethoxysilane, ⁇ -glycidyloxypropyltrimethoxysilane, and acrylate or methacrylate having an Si—O bond at some part of the backbone chain.
  • the resin-cemented optical element of the present invention may include, e.g., lenses, prisms and diffraction gratings.
  • the present invention can bring about superior effects especially when applied to aspheric lenses.
  • the present invention may also be applied to aspheric mirrors.
  • the optical element of the present invention is suited to optical articles (or devices) such as still cameras especially required to be made small-size and/or light-weight, such as analog still cameras and digital still cameras, video cameras, and interchangeable lens systems for these cameras, as well as spectacles, telescopes, binoculars, microscopes and optical disk/magneto-optic disk reading pickup lens systems. Accordingly, the present invention also provides these optical articles having the optical element of the present invention.
  • the resin layer of the resin-cemented optical element of the present invention can be formed by means of a molding tool the molding surface of which has an inverted shape of the resin shape described above.
  • the thickness of a resin well formed on the outside of the resin layer outer edge at the time of molding can be made much smaller.
  • the present invention provides a mold for molding the resin layer of the resin-cemented optical element; the mold having at its peripheral portion outside a molding surface a concavely curved surface which has a larger curvature than the molding surface.
  • the resin layer surface (its base member side being regarded as the back) may be either of a concave surface and a convex surface. It may be used also for the molding of a lens having both the concave surface and the convex surface. It is effective especially when used for the molding of a concave lens (a lens the resin layer surface of which has a concave shape).
  • the concavely curved surface at the molding surface peripheral portion may preferably be at least 0.1 mm outside the effective-diameter region, and more preferably be at least 0.2 mm outside the effective-diameter region.
  • the edge of the curved surface (the position at which the curved surface begins as viewed on the inside of the effective-diameter region, i.e., the position at which the curvature changes from the curvature of the molding surface) may preferably be not distant by 0.5 mm or more from the effective-diameter region.
  • the concavely curved surface may preferably be so hollowed inward that a cross section embracing an axis corresponding to the optical axis of the resin layer to be molded forms an inverted arc. Its curvature may appropriately be determined as long as it is larger than that of the molding surface, and may usually be 0.6 to 1.5 mm in radius.
  • the distance between the base member of the element to be molded and the outer edge of the mold may preferably be so set as to be 1 mm or shorter.
  • the mold of the present invention may be produced by cutting or grinding, depending on materials.
  • a cuttable material such as electroless nickel plating (nickel formed by electroless plating)
  • motion transfer type cutting may be performed by the use of a cutting tool having a cutting surface with a small curvature. This enables formation of the concavely curved surface at the molding surface peripheral portion of the mold.
  • the mold in order to achieve mass production of optical elements, it is preferable to produce the mold with use of a hard material such as single-crystal silicon, SiC, CVD(chemical vapor deposition)-SiC, WC, SKD or hardened steel.
  • a hard material such as single-crystal silicon, SiC, CVD(chemical vapor deposition)-SiC, WC, SKD or hardened steel.
  • These materials can not be shaped by cutting, and must be shaped by grinding.
  • the cutting object and the cutting tool may interfere with each other, and hence any concavely curved surface having a large curvature (i.e., having a small curvature radius) can not be formed.
  • a form grinding wheel having a grinding surface in an inverted shape of at least part of the molding surface of the mold to be produced may be used so that the shape of the grinding surface can be transferred.
  • a mold having the concavely curved surface having a large curvature can be obtained.
  • a concavely curved surface having a small curvature radius e.g., a curvature radius of 3 mm or smaller
  • This form grinding wheel can be produced by, e.g., cutting a cuttable material such as brass to prepare a form grinding wheel base originally, and bonding abrasive grains to its grinding surface.
  • abrasive grains it is preferable to use hard abrasive grains such as particles of single-crystal or polycrystalline diamond or CBN (cubic boron nitride).
  • the abrasive grains may be bonded by plating with a nickel alloy or the like.
  • the resin layer is irradiated by light (ultraviolet rays) on the side of the base member, and a mold made of metal is used as the mold.
  • a transparent material such as glass may also be used as the mold.
  • the resin composition can be cured by irradiation on the mold side, and hence the base member need not be transparent.
  • the resin composition was irradiated by ultraviolet rays 53 for 5 minutes by means of a high-pressure mercury lamp at an illumination of 10 mW/cm 2 to effect curing to form a resin layer 11 having thickness distribution shown in FIG. 6.
  • the glass base member 10 was pushed with an ejector at the former's peripheral portion 54 to release the resin layer 11 from the metal mold 52 to obtain a PAG lens.
  • the resin layer was formed in an external diameter of 38 mm, a maximum resin thickness of 850 ⁇ m, a resin thickness outside the effective-diameter region (within 1 mm from the peripheral edge of the resin layer), of 300 ⁇ m or smaller, and a resin quantity of 700 mg.
  • the amount of deformation of glass at the time of mold release was 20 ⁇ m.
  • the resin layer of the PAG lens obtained in the present Example has a large aspherical shape in a maximum thickness of 850 ⁇ m and a minimum thickness of 100 ⁇ m. Even though the resin layer was molded in such a large aspherical shape, the desired aspherical shape was exactly transferred, and a PAG lens having a precise aspherical surface was obtainable without any break of the base member at the time of mold release. Ten PAG lenses were produced in the same manner as the above. As the result, any break of the base member did not occur at all in all the lenses.
  • a PAG lens was molded using a metal mold having the concavely curved surface at the molding surface peripheral portion.
  • a cross section of an aspherical surface metal mold 70 cut along a plane embracing an axis 71 (in the present Example, the axis of rotation) corresponding to the optical axis of the lens to be molded, is shown in FIG. 7.
  • An enlarged view of its peripheral portion 72 is shown in FIG. 8 in a state held at the time of molding.
  • the metal mold 70 used in the present Example has, as shown in FIGS. 7 and 8, a concavely curved surface 73 at the molding surface peripheral portion.
  • This concavely curved surface 73 is so formed that the cross section embracing an axis 71 corresponding to the optical axis of the resin layer to be molded forms an inverted arc having a curvature radius of 1 mm.
  • the position 83 at which the curved surface begins as viewed on the side of the effective-diameter region is kept at 0.3 mm outside the effective-diameter region (diameter: 33.4 mm) of the lens to be molded.
  • the concavely curved surface 73 is provided at the molding surface peripheral portion.
  • a resin well 81 can be made much thinner than a resin well 82 formed at the time of molding when the metal mold 52 of Example 1 is used.
  • the metal mold 70 of the present Example was produced in the following way. First, brass was cut to originally prepare a form grinding wheel base 90 shown in FIG. 9A, and nickel alloy plating was applied to its grinding surface by the use of a plating solution mixed with abrasive grains. Thus, as shown in FIG. 9B, a form grinding wheel 92 having a plating layer 91 having abrasive grains on its surface was obtained. The grinding surface of this form grinding wheel 92 has an inverted shape of the molding surface of the metal mold 70 to be ground. More specifically, a convexly curved surface 93 is provided at the inner periphery of the grinding surface.
  • the grinding wheel 92 was rotated and a grinding fluid 96 was fed to the grinding surface, during which the surface of the mold 70 on its molding surface side was pressed against the grinding surface of the grinding wheel 92 to transfer the shape of the grinding wheel 92 to the surface of the mold 70 .
  • the mold 70 shown in FIGS. 7 and 8 was obtained, having the concavely curved surface 73 at the peripheral portion on the outside of the molding surface.
  • PAG lenses were produced in the same manner as in Example 1 except that the aspherical mold 70 produced as described above was used in place of the aspherical mold 52 . As the result, any break of the base member did absolutely not occur in all the lenses.

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Surface Treatment Of Glass (AREA)
US09/995,832 2000-11-30 2001-11-29 Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article Abandoned US20020064575A1 (en)

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US11/175,259 US7622181B2 (en) 2000-11-30 2005-07-07 Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article
US12/564,680 US7931833B2 (en) 2000-11-30 2009-09-22 Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article

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JP2000-365992 2000-11-30
JP2000365992 2000-11-30
JP2001-231933 2001-07-31
JP2001231933A JP2002228805A (ja) 2000-11-30 2001-07-31 樹脂接合型光学素子及びその成形型並びに光学物品

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US11/175,259 Expired - Fee Related US7622181B2 (en) 2000-11-30 2005-07-07 Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article
US12/564,680 Expired - Fee Related US7931833B2 (en) 2000-11-30 2009-09-22 Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article

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US12/564,680 Expired - Fee Related US7931833B2 (en) 2000-11-30 2009-09-22 Resin-cemented optical element, mold therefor, fabrication process thereof, and optical article

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US20060001983A1 (en) * 2004-07-02 2006-01-05 Hon Hai Precision Industry Co., Ltd Aspheric lens and method for making same
US20060012889A1 (en) * 2003-04-21 2006-01-19 Tadao Kojima Resin composition for hybrid lens, method for producing hybrid lens, hybrid lens and lens system
CN103370182A (zh) * 2011-02-16 2013-10-23 柯尼卡美能达株式会社 光学元件的制造方法和光学元件
US20200182752A1 (en) * 2018-12-05 2020-06-11 Showa Denko K.K. METHOD OF ACQUIRING SAMPLE FOR EVALUATION OF SiC SINGLE CRYSTAL
CN111505746A (zh) * 2019-01-31 2020-08-07 佳能株式会社 复合光学元件、光学装置和摄像装置

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CN101545993B (zh) * 2008-03-26 2012-04-18 江苏宜清光电科技有限公司 复眼透镜模具及其制造工艺
JP5511287B2 (ja) * 2008-09-30 2014-06-04 Hoya株式会社 プラスチックレンズの製造方法
JP5713555B2 (ja) * 2009-11-25 2015-05-07 キヤノン株式会社 複合型レンズ、それを有する光学系及び光学機器
CN115755321B (zh) * 2022-11-11 2024-08-20 福建福特科光电股份有限公司 一种凹非球面镜片的加工方法

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JP2002228805A (ja) 2002-08-14
CN1208632C (zh) 2005-06-29
CN100588531C (zh) 2010-02-10
CN1356564A (zh) 2002-07-03
US20100007036A1 (en) 2010-01-14
US7622181B2 (en) 2009-11-24

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