WO2010061728A1 - 光学素子の製造方法及び成形金型 - Google Patents
光学素子の製造方法及び成形金型 Download PDFInfo
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- WO2010061728A1 WO2010061728A1 PCT/JP2009/069177 JP2009069177W WO2010061728A1 WO 2010061728 A1 WO2010061728 A1 WO 2010061728A1 JP 2009069177 W JP2009069177 W JP 2009069177W WO 2010061728 A1 WO2010061728 A1 WO 2010061728A1
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- Prior art keywords
- mold
- resin
- optical element
- gate portion
- molding
- Prior art date
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- 238000000465 moulding Methods 0.000 title claims description 109
- 230000003287 optical effect Effects 0.000 title claims description 73
- 238000004519 manufacturing process Methods 0.000 title claims description 22
- 239000011347 resin Substances 0.000 claims abstract description 96
- 229920005989 resin Polymers 0.000 claims abstract description 96
- 230000007246 mechanism Effects 0.000 claims description 21
- 238000002347 injection Methods 0.000 claims description 17
- 239000007924 injection Substances 0.000 claims description 17
- 238000001746 injection moulding Methods 0.000 claims description 16
- 239000011810 insulating material Substances 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 7
- 238000009826 distribution Methods 0.000 claims description 3
- 238000007789 sealing Methods 0.000 claims 1
- 230000006866 deterioration Effects 0.000 abstract description 6
- 238000003780 insertion Methods 0.000 description 34
- 230000037431 insertion Effects 0.000 description 34
- 238000007493 shaping process Methods 0.000 description 6
- 230000004048 modification Effects 0.000 description 5
- 238000012986 modification Methods 0.000 description 5
- 230000005540 biological transmission Effects 0.000 description 4
- 238000003384 imaging method Methods 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005429 filling process Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 201000009310 astigmatism Diseases 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000003028 elevating effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000002040 relaxant effect Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0025—Preventing defects on the moulded article, e.g. weld lines, shrinkage marks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2701—Details not specific to hot or cold runner channels
- B29C45/2708—Gates
- B29C45/2711—Gate inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/38—Cutting-off equipment for sprues or ingates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
- B29L2011/0016—Lenses
Definitions
- the present invention relates to an optical element manufacturing method and a molding die.
- a lens with a high NA with an image-side numerical aperture NA of 0.8 or more such as an objective lens for an optical pickup device or an imaging lens for a mobile phone
- NA numerical aperture
- the optical performance of the lens must be molded accurately. It is desirable not to provide a stress concentration mold member that narrows the flow path.
- an object of the present invention is to provide a method for manufacturing an optical element such as a lens capable of forming a stress concentration portion while preventing deterioration of the fluidity of the resin at the gate portion.
- Another object of the present invention is to provide a molding die suitable for carrying out the above-described optical element manufacturing method.
- an optical element manufacturing method is an optical element corresponding to an optical element among molded products formed in a mold part composed of a first mold and a second mold.
- the stress concentration portion refers to a notch-shaped portion formed near the gate portion of the molded product. That is, it refers to a portion (dent) where stress is concentrated to break.
- the shape of the gate portion is a cylindrical shape. In this case, stable resin fluidity in the gate portion can be ensured.
- the notch molding member is advanced and retracted into the resin circulation space at the gate portion by a variable mechanism.
- the notch molding member is retracted by the variable mechanism, so that the resin can be filled without hindering the resin fluidity.
- the stress concentration portion of a desired size can be formed in a part of the gate portion by advancing the notch forming member by a variable mechanism.
- the notch forming member is advanced and retracted from a pair of opposing side surface portions of the gate portion.
- the stress concentration part which made the flow-path cross-section narrower can be formed by providing the notch forming member in a pair of opposing side surface parts of the gate part.
- the notch molding member is inserted before the gate seal after the resin is filled in the resin molding space and the resin circulation space.
- the resin in the gate portion is not cured, the resin deformation load in the gate portion is reduced, and the notch molding member can be easily inserted.
- the inserted notch forming member reduces the cross-sectional area of the gate portion, so that the gate seal can be formed earlier than usual.
- the notch molding member is inserted after the gate seal after the resin is filled in the resin molding space and the resin circulation space.
- inserting the notch molding member after the gate seal makes it difficult for the pressure at the time of insertion of the notch molding member to be transmitted to the resin molding space side, thereby minimizing the effect of pressure on the optical element. it can.
- the notched molding member is held in a state where it is inserted into the resin flow space side until the molded product is released from the first mold, and the molded product is removed from the first mold. It is also used as an ejector pin for projecting a molded product when releasing the mold. In this case, by combining the notch molding member and the ejector pin, the notch molding member is not pushed forward and backward until it is released, so that the notch molding member is not easily removed from the mold part. And deformation of the optical element can be prevented.
- the notch forming member is formed of a heat insulating material.
- the heat of the resin is difficult to escape due to the heat insulating material, it does not lead to rapid curing, so that the resin can be cured while relaxing the stress even if a notch molding member is inserted.
- the notch forming member may be partially formed of a heat insulating material.
- the molding die according to the present invention can be connected to an injection nozzle of an injection molding machine and corresponds to a sprue portion corresponding to a sprue portion of a molded product, and extends radially from the sprue portion and corresponds to a plurality of runner portions of the molded product.
- a runner portion, a gate portion provided at the tip of the runner portion and corresponding to the gate portion of the molded product, an optical element portion provided at the tip of the gate portion and corresponding to the optical element of the molded product, and a resin in the gate portion A notch molding member that can be advanced and retracted toward the flow space side, and a convex portion is formed on a part of the gate portion when the notch molding member enters the resin flow space side at the gate portion.
- the resin fluidity is prevented by the notch molding member during resin filling by inserting the notch molding member into the resin flow path space after filling the resin molding space with the resin. Can be prevented.
- a stress concentration part can be formed in a part of gate part, preventing the deterioration of the performance of an optical element.
- FIG. 1st Embodiment It is a sectional side view explaining the structure of the shaping die of 1st Embodiment.
- (A), (B) is an expanded sectional view of the molding die of FIG. (A) is sectional drawing of a molded article, (B) is a sectional side view of a lens. It is a front view explaining a shaping
- (A) to (C) are views for explaining an optical element molding die according to a third embodiment.
- (A), (B) is a figure explaining the optical element shaping die of 4th Embodiment. It is a figure which shows the modification of operation
- FIG. 1 is a side sectional view for explaining the structure of the molding die 40
- FIG. 2A is an enlarged sectional view of a P1 portion of FIG. 1
- FIG. It is an expanded sectional view of the gate part GP.
- 3A is a cross-sectional view of a molded product MP molded by the molding die 40 shown in FIG. 1
- FIG. 3B is a diagram of the lens OL cut from the molded product MP of FIG. It is a sectional side view.
- the molding die 40 of this embodiment includes a fixed die 41 and a movable die 42.
- the fixed mold 41 and the movable mold 42 can be opened and closed with the parting line PL as a boundary.
- a resin for molding the lens OL shown in FIG. 3 (B) is obtained by mold-clamping the fixed mold 41 and the movable mold 42 together.
- a mold space CV that is a molding space is formed, and a flow path portion FC that is a resin distribution space for supplying resin to each mold space CV is formed.
- the mold space CV includes a main body space CV1 sandwiched between a pair of optical transfer surfaces S1 and S2, and a flange space CV2 surrounded by a pair of peripheral transfer surfaces S3 and S4.
- the flow path portion FC is configured by a sprue portion SN, a runner portion RN, and a gate portion GN of the molded product MP, a runner portion RP, and a gate portion GP.
- the molded product MP injection-molded by the molding die 40 includes a plurality of lenses OL, and the resin filling space corresponding to the molded product MP is formed from the sprue portion SP.
- the runner portion RP is branched into a plurality of portions, and the mold space CV communicates with the leading end portion of each branched runner portion RP via the gate portion GP.
- Each runner portion RP, each gate portion GP, and each mold space CV are arranged at equal distances from the center of each sprue portion SP.
- An extended sprue portion SS corresponding to an extended sprue SQ described later is formed on the runner portion RP facing the sprue portion SP.
- a mold space CV which is a space between both molds 41 and 42, corresponds to the shape of a lens OL (see FIG. 3 and the like) as an optical element of the molded product MP.
- the lens OL is made of plastic and includes a center portion OLa as an optical function portion having an optical function, and an annular flange portion OLb extending from the center portion OLa in the outer diameter direction.
- the center portion OLa corresponds to the main body space CV1
- the flange portion OLb corresponds to the flange space CV2.
- This lens OL is an objective lens for an optical pickup device, for example, has a high thickness deviation ratio (a state in which the thickness of the optical element has changed abruptly), is compatible with BD, DVD and CD, and is used for BD. It is a lens that satisfies NA 0.85 with respect to a light flux having a wavelength.
- the fixed mold 41 has a circular optical transfer surface S1 corresponding to the optical surface OS1 of the lens OL on the mold surface facing the movable mold 42, and the lens OL.
- a grooved runner recess S7 A sprue portion SP for injecting resin is formed at the center of the fixed mold 41 (see FIG. 1).
- the movable mold 42 has a circular optical transfer surface S2 that is a portion corresponding to the optical surface OS2 of the lens OL on the mold surface facing the fixed mold 41, and the lens OL.
- An extension sprue portion SS is formed at the center of the fixed mold 41 (see FIG. 1).
- the movable mold 42 further includes an insertion hole 44 and a notch forming member 45.
- the insertion hole 44 has a structure for inserting the notch forming member 45, and the rear end surface side (A side in FIG. 1) of the movable mold 42 from the vicinity of the boundary between the mold space CV and the gate portion GP. It is a columnar space formed so as to penetrate through. As shown in FIG. 2A, the insertion hole 44 includes a small-diameter insertion hole 44a on the gate recess S6 side and a large-diameter insertion hole 44b on the rear end surface side of the movable mold 42, and the gate recess S6. The side is getting thinner step by step. Further, the length in the AB direction of the small-diameter insertion hole 44 a of the insertion hole 44 is set so that the notch-forming member 45 can advance and retreat in the insertion hole 44. It is shorter than the length of.
- the notch forming member 45 is provided in the gate recess S6 of the movable mold 42, that is, a part of the gate portion GP, and is for forming the stress concentration portion CN in the gate portion GN of the molded product MP. .
- the notch molding member 45 is composed of a small diameter portion 45a on the gate recess S6 side and a large diameter portion 45b on the rear end face side of the movable mold 42, and the gate recess S6 side is stepwise. It has a cylindrical shape that becomes thinner.
- the notch forming member 45 enters the gate portion GP and forms a cylindrical convex portion on the gate portion GP.
- the notch molding member 45 described later is formed of a heat insulating material so that the resin in the vicinity of the notch molding member 45 is not rapidly cured.
- the heat insulating material is a low heat conductive material having a lower thermal conductivity than this.
- a metal material such as 6-4Ti
- a resin material such as polyimide
- a ceramic such as zirconia or alumina
- the notch forming member 45 is inserted into the insertion hole 44 as described above, and can advance and retreat within the insertion hole 44.
- the outer diameter of the small diameter portion 45 a substantially matches the inner diameter of the small diameter insertion hole portion 44 a of the insertion hole portion 44
- the outer diameter of the large diameter portion 45 b is the inner diameter of the large diameter insertion hole portion 44 b of the insertion hole portion 44. Is approximately the same.
- the boundary K between the notch forming member 45 and the insertion hole 44 in the vicinity of the gate portion GP is a gap that does not allow the resin injected into the mold space CV or the like to enter.
- the base of the notch forming member 45 is connected to a variable mechanism 50 provided outside the movable mold 42, and the notch forming member 45 can be moved back and forth by the variable mechanism 50. It is possible.
- the variable mechanism 50 advances and retracts the notch molding member 45 in accordance with the timing of resin inflow into the mold space CV. Specifically, during resin filling, as shown in FIG. 2 (A), the movable die is moved by retracting the small-diameter portion 45a of the notch molding member 45 until the tip surface thereof coincides with the surface position of the gate portion GP. 42. On the other hand, after filling the resin, as shown in FIG. 2B, the small-diameter portion 45a is advanced into the gate portion GP so that the tip surface protrudes from the surface position of the gate portion GP, and cut into the molded product MP. A notch, that is, a convex portion F1 for forming the stress concentration portion CN is formed.
- the length in the diameter direction perpendicular to the parting line PL of the gate portion GP of the convex portion F1 is, for example, not more than half of the diameter of the gate portion GP (preferably not less than 1/10 and not more than 1/3 of the diameter of the gate portion GP). ). If the length is longer than that, a difference in friction occurs between the lens OL and the runner portion RN when the molded product MP is taken out, and stress concentrates on the stress concentration portion CN. If it does so, a deformation
- the notch forming member 45 has a function as an eject pin.
- the notch forming member 45 as an eject pin is operated by a variable mechanism 50 in FIG. 4 described later, and advances to the fixed mold 41 side (B side in FIG. 1) or on the opposite side (A side in FIG. 1). It can be retreated.
- FIG. 4 is a front view illustrating a molding apparatus for carrying out the manufacturing method of the present embodiment.
- the illustrated molding apparatus 100 includes an injection molding machine 10 that is a main body part that performs injection molding to produce a molded product MP, a take-out device 20 that is an accessory part that takes out the molded product MP from the injection molding machine 10, and a molding apparatus 100. And a control device 30 for comprehensively controlling the operation of each unit constituting the.
- the injection molding machine 10 includes a fixed platen 11, a movable platen 12, a mold clamping plate 13, an opening / closing drive device 15, and an injection device 16.
- the injection molding machine 10 enables molding by sandwiching a movable mold 42 and a fixed mold 41 between the movable platen 12 and the fixed platen 11 and clamping both molds 41 and 42.
- mold opening and mold closing are in the horizontal direction.
- An injection molding machine that opens and closes the mold in the vertical direction may be used.
- the fixed platen 11 is fixed to the center of the support frame 14 so as to face the movable platen 12, and supports the take-out device 20 on the upper part thereof.
- the stationary platen 11 detachably supports the stationary mold 41. Note that the fixed platen 11 is fixed to the mold clamping plate 13 via a tie bar so that it can withstand the pressure of mold clamping during molding.
- the movable platen 12 is supported by a slide guide 15a so as to be movable back and forth with respect to the fixed platen 11.
- the movable platen 12 detachably supports the movable mold 42.
- a variable mechanism 50 is incorporated in the movable platen 12.
- the notch forming member 45 as the eject pin shown in FIG. 1 is operated from the variable mechanism 50 to push the lens OL of the molded product MP in the movable die 42 toward the fixed die 41, and the take-out device 20 Enable transfer.
- the variable mechanism 50 is configured to fix the runner portion (not shown) of the molded product MP in the movable mold 42 by an eject pin (not shown) that mechanically operates in conjunction with a notch forming member 45 as an eject pin. Extrude to the mold 41 side.
- the mold clamping machine 13 is fixed to the end of the support frame 14.
- the mold clamping machine 13 supports the movable board 12 from the back via the power transmission part 15d of the opening / closing drive device 15 at the time of mold clamping.
- the opening / closing drive device 15 includes a slide guide 15a, a power transmission unit 15d, and an actuator 15e.
- the slide guide 15a supports the movable platen 12 and enables a smooth reciprocating movement in the advancing / retreating direction of the movable platen 12 with respect to the fixed platen 11.
- the power transmission unit 15 d expands and contracts by receiving a driving force from an actuator 15 e that operates under the control of the control device 30.
- the movable platen 12 moves toward and away from the fixed platen 11 and moves freely.
- the fixed platen 11 and the movable platen 12 move toward and away from each other, and the fixed die 41 is movable. Mold clamping and mold opening with the mold 42 are performed.
- the injection device 16 includes a cylinder 16a, a raw material reservoir 16b, a screw 16c, and a resin injection end 16d.
- the injection device 16 operates at an appropriate timing under the control of the control device 30, and can discharge the molten resin from the resin injection end 16d in a temperature-controlled state.
- the injection device 16 can detachably connect the resin injection end 16d of the cylinder 16a to the sprue portion SP (see FIG. 1) of the fixed platen 11, and is movable with the fixed mold 41 via the fixed platen 11.
- the molten resin can be supplied at a desired timing to the flow path portion FC communicating with the mold space CV (see FIG. 1) formed in a state where the mold 42 is clamped.
- the temperature adjusting device 17 is a part that adjusts the temperature of the molds 41 and 42 of the injection molding machine 10.
- the temperature adjustment device 17 has a temperature adjustment circuit, and the temperature of the fixed mold 41 and the movable mold 42 can be adjusted. Specifically, for example, the fixed mold 41 and the movable mold 42 are heated to a necessary temperature by supplying a temperature adjusting medium to a fluid circulation path provided in the fixed platen 11 and the movable platen 12. The temperature may be adjusted using a heater or the like without using a medium.
- the take-out device 20 includes a hand 21 that can hold the molded product MP and a three-dimensional drive device 22 that moves the hand 21 three-dimensionally.
- the take-out device 20 operates at an appropriate timing under the control of the control device 30.
- the molded product MP remaining in the movable die 42 after the fixed die 41 and the movable die 42 are separated from each other and opened. It has a role of gripping and carrying it out.
- the control device 30 includes an opening / closing control unit 31, an injection device control unit 32, an ejector control unit 33, and a take-out device control unit 34.
- the opening / closing control unit 31 enables the molds 41 and 42 to be clamped and opened by operating the actuator 15e.
- the injection device controller 32 causes the resin to be injected at a desired pressure into the mold space CV formed between the molds 41 and 42 by operating the screw 16c and the like.
- the ejector control unit 33 operates the variable mechanism 50 to push out the molded product MP remaining on the movable mold 42 from the movable mold 42 when the mold is opened.
- the take-out device control unit 34 operates the take-out device 20 to grip the molded product MP remaining in the movable mold 42 after mold opening and mold release and carry it out of the injection molding machine 10.
- FIG. 5 is a front view for explaining the structure of the ultrasonic breaking device 70.
- the ultrasonic breaking device 70 includes a fixed table 71, an ultrasonic vibration horn 72, an elevating mechanism 73, an ultrasonic vibration device 74, and an ultrasonic vibration control device 75.
- the fixed table 71 is a cylindrical table on which the molded product MP molded by the molding apparatus 100 is placed.
- a mounting plate 76 formed of an elastic member such as rubber is provided on the upper end surface of the fixed table 71.
- a clearance hole 76a for inserting an extension sprue SQ formed below the molded product MP is formed in the center of the fixed table 71 and the mounting plate 76.
- the ultrasonic vibration horn 72 is a bottomed cylindrical ultrasonic vibration transmission portion provided coaxially with the fixed table 71.
- the lower end surface 72 b of the ultrasonic vibration horn 72 is an annular contact plane orthogonal to the long axis PX of the ultrasonic vibration horn 72.
- a sprue insertion hole 72 a into which the sprue SN of the molded product MP can be inserted is provided at the lower central portion of the ultrasonic vibration horn 72.
- the center of the sprue insertion hole 72a of the ultrasonic vibration horn 72 and the center of the escape hole 76a of the fixed table 71 are coincident.
- the ultrasonic vibration horn 72 is connected to the lifting mechanism 73 and the ultrasonic vibration device 74, and is lifted and lowered on the fixed table 71 by the lifting mechanism 73, and ultrasonic vibration is given by the ultrasonic vibration device 74.
- the amplitude of the ultrasonic vibration by the ultrasonic vibration device 74 is controlled by the ultrasonic vibration control device 75.
- FIG. 6 is a flowchart conceptually illustrating the operation of the molding apparatus 100 shown in FIG. 4 and the operation of the ultrasonic breaking apparatus 70 shown in FIG.
- the temperature adjusting device 17 of the molding apparatus 100 is operated to heat both molds 41 and 42 to a temperature suitable for molding (step S10).
- the opening / closing drive device 15 is operated to advance the movable platen 12 to start mold closing (step S11).
- the movable platen 12 moves to the fixed platen 11 side to the die contact position where the fixed die 41 and the movable die 42 are in contact with each other, and the die closing is completed.
- mold clamping is performed to clamp the fixed mold 41 and the movable mold 42 with necessary pressure (step S12).
- step S13 first step.
- a filling process is performed in which the mold space CV between the clamped fixed mold 41 and the movable mold 42 is filled with resin.
- the injection molding machine 10 keeps the resin pressure in the mold space CV at a required level.
- the variable mechanism 50 is operated to insert the notch forming member 45 into the gate part GP and form the convex part F1 on the gate part GP. (See FIG. 2B).
- the stress concentration part CN is formed in the gate part GN of the molded product MP (step S14: second step).
- the notch forming member 45 inserted into the gate portion GP is held as it is until it functions as an ejector pin when the molded product MP is released.
- the mold space CV and the flow path portion FC are appropriately heated by the temperature adjusting device 17, and the molten resin supplied from the injection device 16 is gradually cooled. It waits for solidification to be completed (step S15).
- the mold clamping is finished, and the opening / closing drive device 15 is operated to perform mold opening for retracting the movable platen 12 (step S16).
- the movable mold 42 moves backward, and the fixed mold 41 and the movable mold 42 are separated.
- the molded product MP that is, the lens OL is released from the fixed mold 41 while being held by the movable mold 42.
- variable mechanism 50 is operated to eject the molded product MP (step S17). Specifically, the notch forming member 45 as an eject pin is advanced to the B side in FIG. 1, and the gate portion GN is pushed out along the AB direction with good balance. Further, the sprue portion SN and the like of the molded product MP are released from the movable mold 42 by mechanical protrusion by other eject pins (not shown) performed in conjunction with each other.
- the take-out device 20 is operated, and a proper position of the projected molded product MP is gripped by the hand 21 and carried out to the outside (step S18). At this time, the lens OL is not separated from the molded product MP.
- the removed molded product MP is carried into the ultrasonic breaking device 70 and set in the ultrasonic breaking device 70 as shown in FIG. 5 (step S19). That is, the molded product MP is placed on the fixed table 71 of the ultrasonic breaking device 70 and fixed by the ultrasonic vibration horn 72 lowered by the operation of the lifting mechanism 73. As a result, the runner portion RN of the molded product MP is sandwiched between the lower end surface 72 b of the ultrasonic vibration horn 72 and the mounting plate 76. In this state, the lower end surface 72b is in contact with the plurality of runner portions RN at equidistant positions from the center of the sprue portion SN of the molded product MP.
- step S20 third step.
- the lens OL is separated from the molded product MP almost simultaneously.
- the notch molding member 45 is inserted into the gate portion GP after the mold space CV is filled with the resin. It is possible to prevent the stress strain from remaining in the lens OL without disturbing the flow of the lens. Thereby, deterioration of the performance of the lens OL can be prevented.
- the gate portion GP In the case of the conventional manufacturing method, in order to form the stress concentration portion CN for breaking by ultrasonic waves, the gate portion GP needs to be tapered at a certain angle or more (Japanese Patent Laid-Open No. 2002-240108). See the official gazette). However, in order to maintain the angle of the gate portion GP to the optical element, the optical element must be minimized or the runner portion must be made large and thick. In this case, minimizing the optical element is a restriction on the size of the optical element. Further, increasing the gate portion affects the deterioration of the cycle time.
- a high NA lens for example, NA 0.7 or more
- a lens with a high thickness ratio a lens in which the thickness of the molded part has changed abruptly
- the molded product MP is removed from the molding die 40 with the lens OL attached to the molded product MP in order to ensure the accuracy of the lens and efficiently collect a plurality of lenses. It is necessary to release the mold. Therefore, since the lens OL falls if the gate is cut in the molding die as in the prior art, it is not preferable to completely block the gate portion with the notch molding member 45, for example.
- the notch molding member 45 provided near the gate part GP is changed and inserted into the gate part GP side. Is done.
- the resin is pushed by that amount, and a molded product MP having a stress concentration portion CN is formed. Due to such a configuration, the gate portion GP is not narrowed at the time of resin injection, and the width of the gate portion GP can be ensured. Since the injected resin enters without any obstacle, the lens OL has characteristics.
- the stress concentration portion CN is formed after the resin is filled, the stress concentration portion CN can be provided only in the vicinity of the gate portion GP. Therefore, an optical element having a high deviation ratio such as an objective lens for an optical pickup device and an imaging lens for a mobile phone can be manufactured with high accuracy.
- the shape of the gate portion GN can be freely designed.
- the notch molding member 45 can variably adjust the cross section of the gate portion GP. Therefore, by inserting the convex portion F1 before the gate seal, the gate seal can be performed by rapid cooling.
- the molding die according to the second embodiment is a modification of the first embodiment, and parts that are not particularly described are the same as those of the first embodiment.
- FIG. 7A is a cross-sectional view around the mold space CV of the molding die 140 composed of the fixed die 41 and the movable die 42, and FIG. 7B shows the gate when the stress concentration portion is formed. It is sectional drawing of the part GP.
- the fixed mold 41 is provided with an insertion hole 44A and a notch forming member 45A.
- the movable mold 42 is provided with an insertion hole 44B and a notch forming member 45B.
- the insertion holes 44A and 44B and the notch forming members 45A and 45B of the molds 41 and 42 are arranged at positions facing each other.
- the insertion hole 44B and the notch forming member 45B of the movable mold 42 correspond to the insertion hole 44 and the notch forming member 45 of the first embodiment.
- the insertion hole 44A and the notch forming member 45A of the fixed mold 41 have the same structure as the insertion hole 44 and the notch forming member 45 of the first embodiment.
- a separate variable mechanism is also connected to the notch forming member 45A, and the notch forming member 45A can advance and retreat in the insertion hole 44A.
- the notch forming members 45A and 45B enter the gate portion GP, and form a pair of opposed convex portions F1 on the gate portion GP as shown in FIG. 7B. Thereby, the stress concentration part which made the flow path cross-section thinner can be formed.
- the total length in the diameter direction perpendicular to the parting line PL of the gate portion GP of the pair of convex portions F1 is, for example, less than half the diameter of the gate portion GP (preferably 1 / diameter of the diameter of the gate portion GP). 10 to 1/3).
- the molding die according to the third embodiment is a modification of the first embodiment, and parts that are not particularly described are the same as those of the first embodiment.
- FIG. 8A is a view of the movable mold 42 around the mold space CV of the molding mold 240 constituted by the fixed mold 41 and the movable mold 42 as seen from the fixed mold 41 side.
- FIG. 8B is a CC cross-sectional view of the gate portion GP before the stress concentration portion is formed
- FIG. 8C is a CC cross-sectional view of the gate portion GP when the stress concentration portion is formed.
- the movable mold 42 is provided with two insertion holes 44C and 44D and two notch forming members 45C and 45D perpendicular to the parting line PL with the gate portion GP interposed therebetween.
- the insertion holes 44C and 44D and the notch forming members 45C and 45D are arranged at positions facing each other with the gate portion GP interposed therebetween.
- the shapes of the insertion hole portions 44C and 44D and the notch forming members 45C and 45D are triangular prisms, and the flat surface portion E1 substantially coincides with the tangent line of the gate recess portion S6 of the gate portion GP. Further, the shapes of the insertion holes 44C and 44D and the notch forming members 45C and 45D are triangular on the center side of the gate portion GP when viewed from the fixed mold 41 side (see FIG. 8A). ). In the present embodiment, the shape of the gate portion GP is such that the side portions of the gate portion GP are notched forming members 45C so that the notched members 45C and 45D are inserted into the gate portion GP when the stress concentration portion is formed. , 45D (see FIG. 8B, etc.).
- the notch forming members 45C and 45D enter the gate portion GP, and form a pair of opposed convex portions F1 on the gate portion GP as shown in FIG. 8C. Thereby, the stress concentration part which made the flow path cross-section thinner can be formed.
- the total length of the pair of convex portions F1 in the diametrical direction parallel to the parting line PL of the gate portion GP is, for example, not more than half of the diameter of the gate portion GP (preferably 1 / diameter of the diameter of the gate portion GP). 10 to 1/3).
- the molding die according to the fourth embodiment will be described below. Note that the molding die according to the fourth embodiment is a modification of the first embodiment, and parts that are not particularly described are the same as those of the first embodiment.
- FIG. 9A is a view of the movable mold 42 around the mold space CV of the molding mold 340 composed of the fixed mold 41 and the movable mold 42 as seen from the fixed mold 41 side.
- (B) is CC sectional drawing of the gate part GP at the time of stress concentration part formation.
- the movable mold 42 is provided with one insertion hole 44 and a notch forming member 45.
- the center axis QX of the insertion hole 44 and the notch forming member 45 is perpendicular to the parting line PL and is orthogonal to the center axis TX of the gate portion GP.
- the diameters of the insertion hole 44 and the notch molding member 45 are smaller than the diameter of the gate portion GP so that the lens OL is not cut when the molded product MP is released.
- the notch forming member 45 enters the gate portion GP and forms a convex portion F1 that connects the pair of side surfaces of the gate portion GP as shown in FIG. 9B.
- the length of the convex portion F1 in the diametrical direction parallel to the parting line PL of the gate portion GP is, for example, not more than half the diameter of the gate portion GP (preferably not less than 1/10 of the diameter of the gate portion GP and 1 / 3 or less).
- the present invention has been described based on the above embodiments, the present invention is not limited to the above embodiments, and various modifications are possible.
- the notch forming member 45 is inserted into the gate part GP before the gate seal, but as shown in FIG. 10, the notch forming member 45 is inserted into the gate part GP after the gate seal.
- the gate seal standby (step S21) is performed after the resin injection (step S13), and the stress concentration portion is formed after the resin of the gate portion GP is cured to some extent (step S14).
- the gate portion GN is hardened to some extent, even if pressure is applied to the notch forming member 45, the influence of the pressure on the lens OL can be reduced.
- the shape of the tip of the notch forming member 45 is not limited to that shown in the above embodiment, and the cross-sectional shape can be a triangle, a circle, or the like, or the tip can be a pointed shape, a bulb, or the like.
- the shape of the mold space CV provided in the molding die 40 or the like composed of the fixed die 41 and the movable die 42 is not limited to the illustrated shape, and can be various shapes. That is, the shape of the mold space CV is merely an example, and can be appropriately changed according to the use of the lens OL.
- the injection molding machine 10 may be, for example, a hydraulic type or an electric type as long as it can open and close the molding die 40 and the like.
- the lens OL is not limited to plastic, and a glass lens can be manufactured by the molding apparatus 100 incorporating the same molds 41 and 42 and the like.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
Description
以下、本発明の第1実施形態である光学素子の製造方法及び成形金型について、図面を参照しつつ説明する。
以下、第2実施形態に係る成形金型について説明する。なお、第2実施形態に係る成形金型は、第1実施形態を変形したものであり、特に説明しない部分については、第1実施形態と同様であるものとする。
以下、第3実施形態に係る成形金型について説明する。なお、第3実施形態に係る成形金型は、第1実施形態を変形したものであり、特に説明しない部分については、第1実施形態と同様であるものとする。
以下、第4実施形態に係る成形金型について説明する。なお、第4実施形態に係る成形金型は、第1実施形態を変形したものであり、特に説明しない部分については、第1実施形態と同様であるものとする。
11 固定盤
12 可動盤
15 開閉駆動装置
16 射出装置
17 温度調節装置
20 取出し装置
30 制御装置
40,140,240,340 成形金型
41 固定金型
42 可動金型
44,44A,44B,44C,44D 挿入孔部
45,45A,45B,45C,45D 切欠き成形用部材
50 可変機構
70 超音波破断装置
100 成形装置
CV 型空間
FC 流路部分
GP ゲート部分
RP ランナ部分
SP スプル部分
OL レンズ
MP 成形品
GN ゲート部
RN ランナ部
SN スプル部
CN 応力集中部
PL パーティングライン
Claims (13)
- 第1金型と第2金型とで構成される金型部内に形成された成形品のうち光学素子に対応する光学素子部分の樹脂成形空間に、溶融させた樹脂を射出する第1工程と、
樹脂を前記光学素子部分の樹脂成形空間に充填した後であって、前記第1金型と前記第2金型との型開きまでの間に、前記光学素子部分に連通するとともに前記金型部内に形成された前記成形品のゲート部に対応するゲート部分の一部において凸部を有する切欠き成形用部材を、前記ゲート部分において樹脂流通空間側に挿入し成形を行う第2工程と、
前記第1金型と前記第2金型とを離間し、前記第1金型及び前記第2金型から前記成形品を取り出した後、超音波破断装置により前記成形品から前記光学素子を切断する第3工程と、
を備えることを特徴とする光学素子の製造方法。 - 前記ゲート部分の形状は、円柱状であることを特徴とする請求項1に記載の光学素子の製造方法。
- 前記切欠き成形用部材は、可変機構によって前記ゲート部分において前記樹脂流通空間に進退することを特徴とする請求項1又は請求項2に記載の光学素子の製造方法。
- 前記切欠き成形用部材は、前記ゲート部分の一対の対向する側面部分から進退することを特徴とする請求項1から請求項3までのいずれか一項に記載の光学素子の製造方法。
- 前記切欠き成形用部材は、樹脂が前記樹脂成形空間及び前記樹脂流通空間内に充填された後、ゲートシール前に挿入されることを特徴とする請求項1から請求項4までのいずれか一項に記載の光学素子の製造方法。
- 前記切欠き成形用部材は、樹脂が前記樹脂成形空間及び前記樹脂流通空間内に充填された後、ゲートシール後に挿入されることを特徴とする請求項1から請求項4までのいずれか一項に記載の光学素子の製造方法。
- 前記切欠き成形用部材は、前記第1金型から前記成形品が離型されるまで前記樹脂流通空間側に挿入された状態で保持され、前記成形品を前記第1金型から離型させる際に前記成形品を突き出すエジェクタピンとして兼用されることを特徴とする請求項1から請求項6までのいずれか一項に記載の光学素子の製造方法。
- 前記切欠き成形用部材は、断熱材で形成されていることを特徴とする請求項1から請求項7までのいずれか一項に記載の光学素子の製造方法。
- 射出成形機の射出ノズルに接続可能であるとともに成形品のスプル部に対応するスプル部分と、
前記スプル部分から放射線状に延びるとともに前記成形品の複数のランナ部に対応するランナ部分と、
前記ランナ部分の先に設けられるとともに前記成形品のゲート部に対応するゲート部分と、
前記ゲート部分の先に設けられるとともに前記成形品の光学素子に対応する光学素子部分と、
前記ゲート部分において樹脂流通空間側に進退可能な切欠き成形用部材と、
を備え、
前記切欠き成形用部材が前記ゲート部分において樹脂流通空間側に進入した状態において前記ゲート部分の一部に凸部が形成されることを特徴とする成形金型。 - 前記ゲート部分の形状は、円柱状であることを特徴とする請求項9に記載の成形金型。
- 前記切欠き成形用部材は、可変機構によって前記ゲート部分において樹脂流通空間側に進退することを特徴とする請求項9又は請求項10に記載の成形金型。
- 前記切欠き成形用部材は、前記ゲート部分の一対の対向する側面部分から進退することを特徴とする請求項9から請求項11までのいずれか一項に記載の成形金型。
- 前記切欠き成形用部材は、断熱材で形成されていることを特徴とする請求項9から請求項12までのいずれか一項に記載の成形金型。
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JP2012136073A (ja) * | 2010-12-24 | 2012-07-19 | Yazaki Corp | 自動車用室内照明灯レンズ用金型成型方法および室内照明灯レンズ |
WO2016136861A1 (ja) * | 2015-02-25 | 2016-09-01 | コニカミノルタ株式会社 | 成形装置及び成形方法 |
JP2021037679A (ja) * | 2019-09-02 | 2021-03-11 | 日本碍子株式会社 | 成形体の製造方法 |
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CN109641379B (zh) * | 2016-09-05 | 2021-03-26 | 松下知识产权经营株式会社 | 冷却块及无流道注射成形装置 |
KR102546859B1 (ko) * | 2016-12-27 | 2023-06-22 | 미쓰비시 엔지니어링-플라스틱스 코포레이션 | 성형품 및 성형품의 제조 방법 |
CN109974583B (zh) * | 2019-04-11 | 2024-03-26 | 南京信息工程大学 | 一种非接触光学元件表面面形测量装置及方法 |
JP7145246B2 (ja) * | 2021-01-15 | 2022-09-30 | 本田技研工業株式会社 | 射出成形装置及び該射出成形装置で得られる成形品のエジェクト方法 |
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JP2012136073A (ja) * | 2010-12-24 | 2012-07-19 | Yazaki Corp | 自動車用室内照明灯レンズ用金型成型方法および室内照明灯レンズ |
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WO2016136861A1 (ja) * | 2015-02-25 | 2016-09-01 | コニカミノルタ株式会社 | 成形装置及び成形方法 |
JP2021037679A (ja) * | 2019-09-02 | 2021-03-11 | 日本碍子株式会社 | 成形体の製造方法 |
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