WO2013108764A1 - 光学素子の製造方法及び光学素子 - Google Patents
光学素子の製造方法及び光学素子 Download PDFInfo
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- WO2013108764A1 WO2013108764A1 PCT/JP2013/050599 JP2013050599W WO2013108764A1 WO 2013108764 A1 WO2013108764 A1 WO 2013108764A1 JP 2013050599 W JP2013050599 W JP 2013050599W WO 2013108764 A1 WO2013108764 A1 WO 2013108764A1
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- transfer surface
- optical element
- optical
- mold
- molding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/0048—Moulds for lenses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
- B29C69/02—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
-
- 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
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
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- 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
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B7/00—Mountings, adjusting means, or light-tight connections, for optical elements
- G02B7/02—Mountings, adjusting means, or light-tight connections, for optical elements for lenses
- G02B7/022—Mountings, adjusting means, or light-tight connections, for optical elements for lenses lens and mount having complementary engagement means, e.g. screw/thread
Definitions
- the present invention relates to an optical element manufacturing method and an optical element.
- a small lens module is mounted on the optical system of the image pickup unit mounted on devices such as mobile phones and digital cameras. With recent miniaturization and higher functionality of devices, improvements are being made to this lens module, and high-resolution image acquisition is possible.
- the optical element constituting the lens module can be incorporated into the lens module with the edge portion as a reference by integrally forming an edge portion serving as a frame on the outer periphery of the optical function portion. In this case, the assembly process to the lens barrel and the optical axis adjustment of the lens can be simplified.
- Patent Documents 1 and 2 describe a method of manufacturing an optical element having such an edge portion integrally. In the manufacturing methods of Patent Documents 1 and 2, the optical function part is compression-molded by setting the preform in a mold and compressing, and then the edge part is injected to the outer periphery of the optical function part with the mold closed. Molding.
- the molds described in Patent Documents 1 and 2 are composed of two cavities: a compression molding cavity for compression molding and an injection molding cavity for injection molding.
- the optical function part is molded by compression-molding a preform placed on the center part of the mold by an operation of closing the mold using the compression molding cavity. At this time, the compression molding is performed in a state where the mold is completely closed. Next, by injecting molten resin into the injection molding cavity from the gate provided in the mold, the edge portion is molded so as to surround the optical function portion. And after cooling until the resin of the edge part by which injection molding was cooled, a metal mold
- the preform When the preform is compressed to mold the optical function part, if the outer peripheral edge of the preform protrudes from the compression molding cavity to the injection molding cavity, the injection molding cavity is narrowed. In this case, the flow path of the molten resin flowing from the gate in the injection molding cavity is blocked by the outer peripheral edge of the preform that protrudes.
- the amount of protrusion of the preform at the time of compression molding is not constant, but also varies depending on the compression molding material and the compression molding conditions. In particular, when the preform is placed in the mold, the preform may be placed out of the center position of the compression molding cavity. In this case, the outer peripheral edge of the optical function part after compression molding is biased in the circumferential direction according to the position shift direction.
- the flow resistance of the molten resin at the time of injection molding differs at the peripheral position of the injection molding cavity, and the position of the weld line is not always a constant peripheral position. Further, because of the flow resistance, the molten resin does not spread over the entire injection molding cavity, and there is a risk that sink marks or chipping may occur in a part of the edge portion. Further, in Patent Document 2, by changing the diameters of the upper mold and the lower mold of a compression mold, the adhesion area between the molten resin and the optical function section of the glass material at the time of injection molding of the copa section is increased. The idea to do is made. However, in Patent Document 2, no consideration is given to ensuring a flow path for the molten resin to achieve a suitable flow.
- the present invention provides an optical element that can always stably produce a high-quality optical element without the flow of the molten resin in the cavity for injection molding being prevented by the protrusion of the outer peripheral edge of the optical function part after compression molding. It is an object of the present invention to provide a method and an optical element manufactured thereby.
- the present invention has the following configuration.
- An optical element manufacturing method for obtaining an optical element by molding using a pair of molding dies composed of a first mold and a second mold Each of the pair of molding dies includes an optical function portion transfer surface for forming the optical function portion, a connection portion transfer surface for forming a connection portion connected to the outer peripheral portion of the optical function surface, and a connection portion transfer surface.
- the pair of molding dies are, when the mold is closed, an optical function part molding cavity formed by the optical function part transfer surface, a connection part molding cavity formed by the connection part transfer surface, an inclined part transfer surface, and an inclined part.
- the optical function part transfer surface of one mold of the pair of molding dies has an inclination angle so that the thickness in the optical axis direction of the optical element increases from the side toward the outer peripheral transfer surface side
- the compression molding material with a volume smaller than the volume of the optical element is put in, and the compression molding material is expanded while closing the mold, so that the shape of the optical function part transfer surface and the connection part transfer surface of the molding die is made into the compression molding material.
- a compression molding step of forming a protruding portion that bulges in Luo edge portion molding cavity side An injection molding step of filling the edge portion molding cavity with a melted injection molding material in a state in which the pair of molding dies are closed, and forming an injection molding portion on the outer periphery of the compression molded molding material;
- the protruding portion is on the mold side of HS1 so that the area of HS1 is 60% or more of the cross-sectional area of the protruding compression molding material.
- a method of manufacturing an optical element that is offset. (2) An optical element manufacturing apparatus that molds an optical element with a pair of molding dies including a first mold and a second mold, Each of the pair of molding dies includes an optical function portion transfer surface for forming the optical function portion, a connection portion transfer surface for forming a connection portion connected to the outer peripheral portion of the optical function surface, and a connection portion transfer surface.
- An inclined portion transfer surface for forming an inclined portion continuous with the outer peripheral portion and an outer peripheral portion transfer surface for forming an outer peripheral portion continuous with the inclined portion transfer surface The pair of molding dies are, when the mold is closed, an optical function part molding cavity formed by the optical function part transfer surface, a connection part molding cavity formed by the connection part transfer surface, an inclined part transfer surface, and an inclined part. It has a cavity formed by an edge part forming cavity formed on the outer peripheral transfer surface that is continuous with the transfer surface, The inclined part transfer surfaces of the first mold and the second mold are expanded so that the thickness in the optical axis direction of the optical element increases from the connection part transfer surface side to the outer peripheral part transfer surface side.
- a compression molding material having a volume smaller than the volume of the optical element is placed on the optical function part transfer surface of one mold of the pair of molding dies, and the compression molding material is expanded while closing the mold to Compression that forms the protruding part that bulges part of the compression molding material from the connection molding cavity to the edge molding cavity, while transferring the shape of the optical function part transfer surface and the connection part transfer surface to the compression molding material.
- the optical function unit has a first optical functional surface and a second optical functional surface having an action of refracting light rays
- the edge part is composed of an inclined part connected to the connection part and other outer peripheral parts, and the optical element cross section including the optical axis is
- Each inclined portion on the first optical function surface side and the second optical function surface side has an inclination angle such that the thickness in the optical axis direction of the optical element increases from the connection portion side toward the outer peripheral portion
- the optical function part and the connection part are formed by compression molding a compression molding material, and the edge part is mainly formed by injection molding, and the injection molding material and the compression molding material are connected from the connection part to the edge part in the edge part.
- a boundary surface is formed by the protruding part that protrudes toward the outside, and the section of the protruding part is divided by a perpendicular bisector perpendicular to the optical axis that bisects the thickness of the connecting part, and the side with the larger area is
- a high-quality optical element can always be obtained stably without hindering the flow of the molten resin in the injection molding cavity due to the protrusion of the outer periphery of the optical function after compression molding.
- the optical element manufacturing process includes a compression molding process in which a preform formed in a spherical shape or a shape close to the final shape of the optical function part is compression molded, and then an injection molding in which an edge part is molded by injection molding on the outer periphery of the lens. It has a two-stage process.
- FIG. 1 is a diagram for explaining an embodiment of the present invention, and is a schematic cross-sectional view of a molding die for molding an optical element as an optical element.
- the molding die 11 includes a first die 13 and a second die 15.
- the state shown in FIG. 1 is a state in which the compression molding material M1 is placed on the second mold 15.
- the compression molding material M1 is a preform made of a synthetic resin material having thermoplasticity and translucency.
- the first mold 13 includes a columnar core portion 17 and a substantially cylindrical body portion 19 in which the core portion 17 is inserted and fitted to the core portion 17 so as to be relatively movable.
- the core portion 17 and the body portion 19 are fixed to each other at the time of compression molding, and relative movement becomes impossible.
- a first transfer surface 21 and a second transfer surface 21 for transferring a predetermined optical function portion shape to the compression molding material M1 are respectively provided on the lower end surface of the first mold 13 and the upper end surface of the second mold 15.
- a transfer surface 23 is formed.
- the first transfer surface 21 includes a first optical function portion transfer surface 21a that is in a range on the inner peripheral side from the end portion S1 of the optical function surface of the core portion 17, an outer periphery from the end portion S1 of the optical function surface, and an inner side from S2. It includes a peripheral connection portion transfer surface 21b, a first inclined portion transfer surface 21c having an inclination angle with respect to the optical axis from S2 to S3, and a first outer peripheral portion transfer surface 21d that is a range on the outer peripheral side of S3. .
- the second transfer surface 23 includes a second optical function portion transfer surface 23a that is an inner peripheral range of the end portion S4 of the optical function surface, and an end portion of the connection portion from the end portion S4 of the optical function portion transfer surface.
- the connecting portion transfer surface 23b up to S5 the second inclined portion transfer surface 23c having an inclination angle with respect to the optical axis from the end S5 to S6 of the connecting portion, and the second outer peripheral portion in the range on the outer peripheral side from S6 A transfer surface 23d.
- FIG. 2 is a partially enlarged cross-sectional view of the molding die with the mold closed.
- a cavity 25 serving as an optical element molding cavity is formed between the first transfer surface 21 and the second transfer surface 23 that are arranged to face each other.
- the cavity 25 is connected to the optical function part molding cavity 27 formed between the first optical function part transfer surface 21a and the second optical function part transfer surface 23a, and the outer periphery of the optical function part molding cavity 27.
- the first connecting portion transfer surface outer peripheral portion transfer surface 21b and the second connection portion outer peripheral portion transfer surface 23b are formed between the annular connection portion forming cavity 28, the first inclined portion transfer surface 21c, and the first inclined portion transfer surface 21c. It has a first outer peripheral portion transfer surface 21d, a second inclined portion transfer surface 23c, and an edge portion molding cavity 29 formed from the second outer peripheral portion transfer surface 23d.
- the distance W is set in a range of 0.5 ⁇ W / d ⁇ 2 with respect to the thickness d of the connection part between the connection part forming cavity 27 and the edge part forming cavity 29.
- it sets to the range of 0.8 ⁇ W / d ⁇ 2, More preferably, it is set to 0.9 ⁇ W / d ⁇ 2.
- the compression molding material M1 can be efficiently directed in a specific direction to be described later. Further, it is desirable to set the value of w / d larger as the compression speed becomes faster.
- the edge portion forming cavity 29 includes a first flat transfer surface 33 and a first side constituting a first inclined portion transfer surface 21c and a first outer peripheral portion transfer surface 21d connected to the end S2 of the first mold 13.
- the first inclined portion transfer surface 21c and the second inclined portion transfer surface 23C, which are the connection portions of the edge portion forming cavity 29 with the connection portion forming cavity 28, are the center of the cavity 25 in the cross section including the lens optical axis Ax. It is set as the cross-sectional shape which expands toward the outer side.
- the compression molding cavity 25 is formed thinner than the maximum thickness of the injection molding cavity 29 in the optical axis Ax direction.
- the compression molding process using the molding die will be described.
- the first mold 13 and the second mold 15 are relatively moved so as to come close to each other.
- the compression molding material M1 heated more than the glass transition temperature Press.
- the shape of a pair of front and back optical functional surfaces is transferred to the compression molding material M1.
- the first mold 13 and the second mold 15 are brought closer to each other.
- the compression molding material M1 is spread between the first optical function portion transfer surface 21a and the second optical function portion transfer surface 23a, and the outer peripheral edge portion of the compression molding material M1 is connected to the first outer periphery transfer surface 21d and the first outer surface transfer surface 21d. 2 Enters the edge portion forming cavity 29 defined between the outer peripheral portion transfer surface 23d.
- the first mold 13 and the second mold 15 are brought close to a state close to the mold closing. Then, the outer peripheral edge portion of the compression molding material M1 is released from the compressive force between the first optical function portion transfer surface 21a and the second optical function portion transfer surface 23a, so that the thickness remains slightly expanded in the optical axis direction. Is kept unchanged. As a result, the outer peripheral edge portion of the compression molding material M1 enters between the first outer peripheral portion transfer surface 21b and the second outer peripheral portion transfer surface 23b and is formed in a state of bulging into the edge portion forming cavity 29. .
- FIG. 4A the bulging end 45 of the compression molding material M1 moves from the connection molding cavity 28 to the edge molding cavity 29 as the compression molding progresses. Move towards
- the protruding portion 47 of the compression molding material M1 is formed along the second inclined portion transfer surface 23c in the edge portion forming cavity 29. It is formed in a state of being shifted to the second mold 15 side.
- a large injection molding material flow space 49 is secured on the side of the first mold 13 opposite to the side on which the protruding portion 47 of the edge portion molding cavity 29 is formed. Since the flow space 49 is formed on the side opposite to the side where the protruding portion 47 is formed, the flow space 49 is not easily affected by space occupation due to variations in the amount of the protruding portion 47.
- the shape of the outer peripheral edge of the compression molding material M1 that protrudes from the connecting portion molding cavity to the edge molding cavity varies depending on the compression amount, compression speed, volume of the compression molding material M1 to be supplied, etc. However, it becomes an indefinite shape.
- FIG. 7 when the cross-sectional area of the protruding portion 47 is seen in the OZ cross section including the optical axis position O that is the center of the optical function portion forming cavity and the maximum protruding position Z, the protruding portion 47.
- the shape of the outer peripheral edge portion of the compression molding material M1 protruding from the connection portion molding cavity to the edge portion molding cavity does not become unstable.
- the area of the protruding portion is less than 60%, the offset effect cannot be sufficiently secured, and it is necessary to increase the outer diameter of the optical element in order to stably secure the flow path of the resin for injection molding. It becomes difficult to increase the space efficiency.
- the shape of the outer peripheral edge portion of the compression molding material M1 protruding from the connection portion molding cavity to the edge portion molding cavity may become unstable.
- the above compression molding process is completed when the first mold 13 and the second mold 15 are in a closed state.
- the optical function part 51 of the optical element and the connection connection part 53 on the outer peripheral side of the optical function part 51 are formed.
- the optical function portion 51 and the connection portion 53 are integrally formed by compressing the compression molding material M1.
- the temperature of the compression molding material M1 is higher than the glass transition temperature in the compression molding process described above, each transfer surface of the molding die is satisfactorily transferred to the compression molding material M1.
- an injection molding process is performed.
- the injection molding process is performed while the first mold 13 and the second mold 15 are closed.
- the injection molding material M2 is partitioned between the first outer peripheral transfer surface 21d and the second outer peripheral transfer surface 23d from the injection gate 55 provided in the first mold 13. Injected into the edge forming cavity 29.
- the edge forming cavity 29 is formed in an annular shape on the outer peripheral side of the compression molding material M1.
- the injection molding material M2 is formed in the injection molding cavity 29 after the first mold 13 and the second mold 15 are closed in the compression molding process and before the temperature of the compression molding material M1 falls below the glass transition temperature. Is injected into. That is, the adhesive force between the compression molding material M1 and the injection molding material M2 can be enhanced by supplying the injection molding material M2 to the edge portion molding cavity 29 while the compression molding material M1 is in a semi-solid state.
- the injected injection molding material M2 is distributed so as to surround the outer periphery of the compression molding material M1 through the edge portion molding cavity 29, and is combined with the compression molding material M1. At this time, the compression molding material M1 and the injection molding material M2 are firmly bonded at the interface 57 by the injection pressure of the injection molding material M2. In this step, the edge portion of the optical element is formed.
- the first mold 13 and the second mold 15 are cooled with the mold closed, and the compression molding material M1 and the injection molding material M2 that are integrated are sufficiently cured. After that, as shown in FIG. 5C, the first mold 13 and the second mold 15 are put into a released state. That is, the first mold 13 is separated from the second mold 15, and the core portion 17 of the first mold 13 is further moved relative to the body portion 19 in the axial direction. By doing so, the optical element 59 onto which the second transfer surface 23 of the second mold 15 has been transferred is peeled off from the second mold 15, and is optically transferred from the first outer peripheral transfer surface 21 d in the body portion 19. The edge 61 of the element 59 is peeled off.
- the molding die having the above-described configuration is performed in the edge portion molding cavity in order to form a mold release control structure by injection molding.
- injection molding since the degree of freedom of the shape of the cavity is high, the mold release resistance of one of the molds (first mold in the case of this configuration example) is increased, and the other mold (second mold). The mold release resistance is low.
- the molded product remains stably in one mold (first mold). That is, the draft of the first side end transfer surface 100 that transfers the side end surface of the outer shape portion of the optical element of the first mold is the removal of the second side end transfer surface 101 that transfers the outer shape portion of the second mold.
- the mold release resistance on the first side end transfer surface 100 side increases, and as a result, the molded product is held on the first mold side when the mold is opened.
- the mold release resistance on the injection molding side can be freely adjusted, so that the molded product can be reliably left in one mold.
- the molded optical element 59 is taken out through the above steps.
- the injection molding material M2 can be spread over the entire edge part molding cavity 29, and the edge part 61 can always be formed stably.
- the outer peripheral edge of the preform after the compression molding protrudes into the edge molding cavity 29. Is not even in the circumferential direction. That is, the amount of protrusion of the compression resin of the preform of the compression molding portion varies depending on the weight (volume) variation of the preform and the placement accuracy on the mold.
- FIG. 6 is an explanatory view schematically showing a state in which the compression molding material M1 protrudes into the edge portion forming cavity 29.
- FIG. In the drawing, the case where the preform is set at a position shifted in the right direction in the drawing from the optical axis position O, which is the center of the cavity for molding the optical function unit, is shown, and the preform is located on the outer peripheral side from the end S5.
- the protruding portion 47 that protrudes is shown as a hatched portion.
- the injection molding material injected from the injection gate 55 into the edge part forming cavity 29 flows through the edge part forming cavity 29 in the directions P1 and P2 in the drawing.
- the side where the center of the preform is shifted is the maximum protruding position Z where the protruding amount is the largest, and the opposite side is small. Therefore, the flow path of the injection molding material tends to be narrower in the P1 direction than in the P2 direction.
- the resin that protrudes in the cross section of the optical axis position O and the maximum protruding position Z is caused by the action of the end portions S2 and S5.
- the mold side is offset so that 60% or more of the cross-sectional area of the protruding compression molding resin is included. Accordingly, it is possible to secure a volume capable of sufficiently absorbing the amount of the protruding resin in consideration of the variation factor of the protruding amount on the first mold side of the edge portion molding cavity 29, and the flow of the injection molding resin can be appropriately flowed. . Therefore, the injection molding material is hardly affected by the deviation of the protruding portion 47, and the flow of the injection molding resin in the edge portion molding cavity 29 is stabilized.
- the injection molding material is filled from the injection gate 55 into the edge part forming cavity, and the edge part is always formed into a fixed shape. Further, the generation position of the weld line WL is stabilized from the injection gate 55 to the farthest position of the injection molding cavity.
- volume control of a preform has been one of the major issues for quality control of a molded product. Since this has been one of the causes of cost increase, a cost reduction effect can be obtained.
- the protrusion of the outer peripheral edge of the connecting portion after compression molding does not hinder the flow of the molten resin in the edge portion forming cavity, thereby reducing the occurrence of component defects. It becomes possible.
- a high-quality optical element can be manufactured stably at all times while taking advantage of compression molding and injection molding.
- the compression molding resin is preferably a light-transmitting synthetic resin.
- the optical element according to the present invention is used not only as a reflecting surface but mainly for the purpose of obtaining a refractive action of light. In particular, since a plurality of optical elements are combined in order to obtain predetermined imaging performance, high optical transparency is desired for the optical elements.
- the internal transmittance per 1 mm thickness is 70% or more, it can be used for a wide range of applications, and more preferable.
- the internal transmittance per 1 mm thickness of the optical element is 70% or less, the amount of light loss increases, so that the application may be limited.
- FIG. 8 is a cross-sectional view of the connecting portion forming cavity and the edge portion forming cavity in the forming die, and includes a first die 13B and a second die 15B.
- the end portions S2 and S5 overlap in the mold closing direction (optical axis direction).
- ⁇ 1 is 30 ° ⁇ ⁇ 1 ⁇ 90 °, preferably 45 ° ⁇ ⁇ 1 ⁇ 90 °
- ⁇ 2 is 0.5 ° ⁇ ⁇ 2 ⁇ 45 °, preferably 0.5 ° ⁇ ⁇ 2 ⁇ 30. It is preferable to make it into °.
- the compression molding material that protrudes from the connection portion molding cavity is smoothly expanded into the edge portion molding cavity 29, and the bonding strength with the injection molding material is improved. Further, the above relationship can be sequentially adjusted in accordance with the relationship between the resin viscosity and the resin protruding speed depending on the compression speed.
- FIG. 9 is an explanatory view schematically showing how the compression molding material M1 bulges out from the compression molding cavity into the edge molding cavity 29.
- Compression molding material M1 is, flow velocity V 2 of the second inclined portion transfer surface 37 side is relatively faster than the flow velocity V 1 of the end portion S2 side connected to the end portion S5. That is, when the compression molding material M1 expands while expanding, a flow velocity difference occurs in each expanding direction, so that the expanding end 45 biases the protruding direction toward the second mold 15 side, It gradually moves up so as to spread into the edge forming cavity 29.
- the injection molding material M2 can be spread over the entire edge part forming cavity 29, and the edge part 61 can always be formed stably. Further, since the protruding portion 47 is offset in the edge portion forming cavity, the flow path of the injection molding material is stably and large secured even if the protruding amount of the protruding portion 47 changes. Are hardly affected by the bias of the protruding portion 47.
- the offset amount of the protruding portion 47 is the optical axis direction of the end portions S2 and S5 of the inclined portion transfer surface. If the cross section of the protruding portion that protrudes into the L edge portion forming cavity 29 is bisected by a perpendicular bisector perpendicular to the optical axis Ax that bisects the thickness, 60% or more of the sectional area of the protruding portion is offset It is preferably included in the direction. In FIG.
- the maximum protruding position is Z in the displacement direction of the preform, but the position of Z is not limited to this, and the portion where the cross-sectional area of the protruding compression molding material M1 is maximum is the maximum.
- the protruding position is Z.
- the edge shaping cavities there can be a plurality of means for aligning the protruding portion protruding from the connecting portion forming cavity in any direction, and they can be freely combined within the intended range. Is possible.
- FIG. 11 is a cross-sectional view including the optical axis Ax of the optical element formed by the first manufacturing method.
- the optical element 59 is formed in a circular optical function portion 51 having the center as an optical axis, a connection portion 53 formed in an annular shape on the outer peripheral edge of the optical function portion 51, and an annular shape on the outer peripheral edge of the connection portion 53, It consists of a plastic material which has the edge part 61 connected with the optical function part 51 by the connection part 53.
- the optical function unit 51 has a pair of optical function surfaces.
- the connection part 53 has a flat connection surface 53A and a connection surface 53B.
- the side surface of the edge portion 61 on the connection portion 53 side has inclined portions 77A and 77B inclined with respect to the optical axis Ax.
- the optical element 59 includes a boundary point between the connection surface 53A of the connection part 53 and the inclined part 77A of the edge part 61, and a lower inclination of the second connection surface 53B of the connection part 53 and the edge part 61 in the optical element cross section.
- the boundary point with the portion 77B is on a different optical axis direction line, and the distance to the optical axis Ax is different.
- the optical element molded by the second manufacturing method is not shown, but similarly to the above, in the cross section of the optical element, the boundary point between the connection surface 53A of the connection part 53 and the upper inclined part of the edge part 61, The boundary point between the connecting surface 53B of the connecting portion 53 and the lower inclined portion of the edge portion 61 is on the same optical axis direction line and has the same distance to the optical axis Ax.
- the amount of offset of the protruding portion 47 is equal to the thickness in the optical axis direction of the end portions S2 and S5 of the inclined portion transfer surface.
- the inclined portion in the shifting direction including 60% or more of the sectional area of the protruding portion is included.
- the absolute value of the tilt angle is larger.
- the interface 57 between the compression molding material M1 and the injection molding material M2 of the edge portion 61 has a protruding margin dimension G of at least 0.2 mm or more from the outermost peripheral end portion 63 of the edge portion 61 over the entire circumference. This does not hinder the flow of the injection molding material M2 in the edge portion molding cavity described above. Further, since the compression molding material M1 does not protrude from the edge molding cavity of the mold and does not reach the mating surface of the pair of molds when the compression molding is closed, there is no possibility of damage to the molding mold. .
- FIG. 12 is a plan view of the molded optical element.
- the edge 61 of the optical element 59 is connected to the protruding receiving surface or pressing surface that comes into contact with the lens barrel when the optical element 59 is accommodated in the lens barrel, or to the front and rear lenses with a fitting structure.
- the joint portions 65A, 65B, and 67, such as the projections, are formed.
- the weak line WL is weakened and overlapped with the thick region.
- the weld line WL is filled with the resin injected from the gate in half by the injection molding cavity. And the surface where each resin merges in the cavity is used as a weld line.
- the mechanical characteristics and optical characteristics are substantially the same.
- various effects can be expected by imparting different characteristics to the injection molding material M2 with respect to the compression molding material M.
- ⁇ Light absorption effect due to colorant ⁇ Light diffusion effect due to mixed material in which resinous material is mixed with particulate material having refractive index different from that of resin material ⁇ Intentional difference in refractive index between compression molding material M1 and injection molding material M2 It is conceivable to control the incident reflection characteristics of the interface by providing the thickness.
- the present invention is not limited to the above-described embodiments, and those skilled in the art can change or apply the configurations based on the combination of the configurations of the embodiments, the description of the specification, and known techniques. This is also the scope of the present invention, and is included in the scope of seeking protection.
- a convex lens is described as an example, but a concave lens may be used, and even in that case, the same effect as described above can be obtained.
- the optical parts made by the molding method combining compression molding and injection molding of the present invention are very thick in the optical axis direction so that the optical function part and connection part formed by compression molding cannot be molded by injection molding. It is necessary to secure the shape and thickness of the edge part formed by injection molding so as not to hinder the flow of resin, but it is difficult to make by compression molding such as fitting between lenses to improve assembly suitability, for example.
- An optical element having a complicated shape can be realized.
- the thinnest part in the optical axis direction of the optical element is included in the optical function part or the connection part.
- the lens according to the present invention can achieve both reduction in thickness and improvement in assembly suitability, it is possible to provide an optical element suitable for a small and thin lens module used in a mobile phone, a smartphone, or the like. Become.
- Each of the pair of molding dies has an optical function portion transfer surface for forming the optical function portion, a connection portion transfer surface for forming a connection portion connected to the outer peripheral portion of the optical function surface, and a connection portion.
- the pair of molding dies are, when the mold is closed, an optical function part molding cavity formed by the optical function part transfer surface, a connection part molding cavity formed by the connection part transfer surface, an inclined part transfer surface, and an inclined part.
- the optical function part transfer surface of one mold of the pair of molding dies has an inclination angle so that the thickness in the optical axis direction of the optical element increases from the side toward the outer peripheral transfer surface side
- the compression molding material with a volume smaller than the volume of the optical element is put in, and the compression molding material is expanded while closing the mold, so that the shape of the optical function part transfer surface and the connection part transfer surface of the molding die is made into the compression molding material.
- a compression molding step of forming a protruding portion that bulges in Luo edge portion molding cavity side An injection molding step of filling the edge portion molding cavity with a melted injection molding material in a state in which the pair of molding dies are closed, and forming an injection molding portion on the outer periphery of the compression molded molding material;
- the protruding portion is on the mold side of HS1 so that the area of HS1 is 60% or more of the cross-sectional area of the protruding compression molding material.
- produces a flow rate difference with respect to each spreading direction of the compression molding material of the resin which flows through the metal mold
- a method of manufacturing an optical element according to (1) or (2) The radial distance from the boundary position between the connecting part transfer surface of the first mold and the inclined part transfer surface to the optical axis is defined as the first boundary position radius, and the connection distance between the connecting part transfer surface of the second mold and the inclined part transfer surface.
- the resin protruding from the mold side having the boundary position having a small value between the first boundary position radius and the second boundary position radius is offset.
- a method for producing an optical element according to any one of (1) to (3) comprising: First absolute value theta 1 of tilt angle of the inclined portion transfer surface and the optical axis of the mold side, the absolute value of the tilt angle of the second inclined portion transfer surface of the mold side and the optical axis theta 2 A method of molding an optical element in which ⁇ 1 and ⁇ 2 are different from each other, and the resin protruding to the mold side having an angle with a small absolute value of the tilt angle is offset.
- a method for producing an optical element according to any one of (1) to (4) A method for manufacturing an optical element, wherein the optical element molding cavity or the connection part molding cavity has the thinnest portion of the optical element molding cavity in the optical axis direction.
- An optical element manufacturing apparatus that molds an optical element with a pair of molding dies including a first mold and a second mold, Each of the pair of molding dies includes an optical function portion transfer surface for forming the optical function portion, a connection portion transfer surface for forming a connection portion connected to the outer peripheral portion of the optical function surface, and a connection portion transfer surface.
- An inclined portion transfer surface for forming an inclined portion continuous with the outer peripheral portion and an outer peripheral portion transfer surface for forming an outer peripheral portion continuous with the inclined portion transfer surface The pair of molding dies are, when the mold is closed, an optical function part molding cavity formed by the optical function part transfer surface, a connection part molding cavity formed by the connection part transfer surface, an inclined part transfer surface, and an inclined part. It has a cavity formed by an edge part forming cavity formed on the outer peripheral transfer surface that is continuous with the transfer surface, The inclined part transfer surfaces of the first mold and the second mold are expanded so that the thickness in the optical axis direction of the optical element increases from the connection part transfer surface side to the outer peripheral part transfer surface side.
- a compression molding material having a volume smaller than the volume of the optical element is placed on the optical function part transfer surface of one mold of the pair of molding dies, and the compression molding material is expanded while closing the mold to Compression that forms the protruding part that bulges part of the compression molding material from the connection molding cavity to the edge molding cavity, while transferring the shape of the optical function part transfer surface and the connection part transfer surface to the compression molding material.
- the protruding portion is offset so that the area of HS1 is 60% or more of the cross-sectional area of the protruding compression molding material.
- Optical element manufacturing equipment (11) An optical element manufacturing apparatus according to (10), When the inclined portion transfer surface forming the edge molding cavity of the molding die expands and protrudes while the compression molding material spreads from the connection portion molding cavity to the edge molding cavity in the optical axis direction, the first portion is formed.
- produces a flow rate difference with respect to each spreading direction of the compression molding material of the resin which flows through the metal mold
- An optical element manufacturing apparatus according to (10) or (11),
- the radial distance from the boundary position between the connecting part transfer surface of the first mold and the inclined part transfer surface to the optical axis is defined as the first boundary position radius, and the connection distance between the connecting part transfer surface of the second mold and the inclined part transfer surface.
- the optical element that moves the resin protruding to the mold side having small values of the first boundary position radius and the second boundary position radius.
- An optical element manufacturing apparatus according to any one of (10) to (12), First absolute value theta 1 of tilt angle of the inclined portion transfer surface and the optical axis of the mold side, the absolute value of the tilt angle of the second inclined portion transfer surface of the mold side and the optical axis theta 2 , An optical element manufacturing apparatus that shifts the resin protruding to the mold side having an angle of ⁇ 1 and ⁇ 2 different from each other and an angle of inclination having a small absolute value.
- the optical function unit has a first optical functional surface and a second optical functional surface having an action of refracting light rays
- the edge part is composed of an inclined part connected to the connection part and other outer peripheral parts, and the optical element cross section including the optical axis is
- Each inclined portion on the first optical function surface side and the second optical function surface side has an inclination angle such that the thickness in the optical axis direction of the optical element increases from the connection portion side toward the outer peripheral portion
- the optical function part and the connection part are formed by compression molding a compression molding material, and the edge part is mainly formed by injection molding, and the injection molding material and the compression molding material are connected from the connection part to the edge part in the edge part.
- a boundary surface is formed by the protruding part that protrudes toward the outside, and the cross section of the protruding part is divided by a perpendicular bisector perpendicular to the optical axis that bisects the thickness of the connecting part, and the side with the larger area is divided.
- HS1 an optical element that is offset so that the area of HS1 is 60% or more of the cross-sectional area of the protruding compression molding material, where HS2 is the smaller area.
- a lens module including at least one optical element of any one of (14) to (16).
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Abstract
Description
また、特許文献2には、圧縮成形用の金型の上型と下型の径を変更することにより、コパ部の射出成型時の溶融樹脂とガラス素材の光学機能部との密着面積を大きくする工夫がなされている。しかし、特許文献2には、溶融樹脂の流路を確保し、好適な流動とすることに関してはなんら考慮されていない。
そこで本発明は、圧縮成形後の光学機能部外周縁のはみ出しによって、射出成形用キャビティ内の溶融樹脂の流動が妨げられることなく、常に安定して高品質の光学素子を製造できる光学素子の製造方法及びこれにより製造された光学素子を提供することを目的とする。
(1) 第1の金型と第2の金型からなる一対の成形用金型を用いる成形加工によって光学素子を得る光学素子の製造方法であって、
一対の成形用金型はそれぞれ、光学機能部を形成するための光学機能部転写面と、光学機能面の外周部に連なる接続部を形成するための接続部転写面と、接続部転写面の外周部に連なる傾斜部を形成するための傾斜部転写面と傾斜部転写面に連なる外周部を形成するための外周部転写面を有し、
一対の成形用金型は型閉時に、光学機能部転写面で形成される光学機能部成形用キャビティと、接続部転写面で形成される接続部成形用キャビティと、傾斜部転写面と傾斜部転写面に連なる外周部転写面で形成されるコバ部成形用キャビティで形成されるキャビティを有し、第1の金型と第2の金型の傾斜部転写面は、それぞれ、接続部転写面側から外周部転写面側に向かって光学素子の光軸方向の厚みが、厚くなるように拡開する傾斜角を有し、一対の成形用金型の一方の金型の光学機能部転写面に光学素子の体積よりも小さな体積の圧縮成形材料を投入し、型を閉じながら圧縮成形材料を押し広げて成形用金型の光学機能部転写面と接続部転写面の形状を圧縮成形材料に転写するとともに、圧縮成形材料の一部を接続部成形用キャビティからコバ部成形用キャビティ側に膨出したはみ出し部を形成する圧縮成形工程と、
一対の成形用金型の型が閉じた状態でコバ部成形用キャビティに溶融した射出成形材料を充填して、圧縮成形された圧縮成形材料の外周に射出成形部を形成する射出成形工程と、を有し、
接続部成形用キャビティの光軸方向の厚みを二等分する光軸に垂直な垂直二等分線で、接続部成形用キャビティからコバ部成形用キャビティにはみ出したはみ出し部の断面形状を二分し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、はみ出した圧縮成形材料の断面積の60%以上となるように、はみ出し部がHS1の金型側に片寄せされている光学素子の製造方法。
(2) 第1の金型と第2の金型からなる一対の成形用金型により光学素子を成形加工する光学素子の製造装置であって、
一対の成形用金型はそれぞれ、光学機能部を形成するための光学機能部転写面と、光学機能面の外周部に連なる接続部を形成するための接続部転写面と、接続部転写面の外周部に連なる傾斜部を形成するための傾斜部転写面と傾斜部転写面に連なる外周部を形成するための外周部転写面を有し、
一対の成形用金型は型閉時に、光学機能部転写面で形成される光学機能部成形用キャビティと、接続部転写面で形成される接続部成形用キャビティと、傾斜部転写面と傾斜部転写面に連なる外周部転写面で形成されるコバ部成形用キャビティで形成されるキャビティを有し、
第1の金型と第2の金型の傾斜部転写面は、それぞれ、接続部転写面側から外周部転写面側に向かって光学素子の光軸方向の厚みが、厚くなるように拡開する傾斜角を有し、
一対の成形用金型の一方の金型の光学機能部転写面に光学素子の体積よりも小さな体積の圧縮成形材料を投入し、型を閉じながら圧縮成形材料を押し広げて成形用金型の光学機能部転写面と接続部転写面の形状を圧縮成形材料に転写するとともに、圧縮成形材料の一部を接続部成形用キャビティからコバ部成形用キャビティ側に膨出したはみ出し部を形成する圧縮成形工程と、
一対の成形用金型の型が閉じた状態でコバ部成形用キャビティに溶融した射出成形材料を充填して、圧縮成形された圧縮成形材料の外周に射出成形部を形成する射出成形工程と、を有し、
接続部成形用キャビティの光軸方向の厚みを二等分する光軸に垂直な垂直二等分線で、接続部成形用キャビティからコバ部成形用キャビティにはみ出した圧縮成形材料の断面形状を二分し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、はみ出した圧縮成形材料の断面積の60%以上となるように、はみ出し部が片寄せされている光学素子の製造装置。
(3) 中心を光軸とする円状の光学機能部と、光学機能部の外周縁に環状に形成された接続部と、接続部の外周縁に環状に形成されたコバ部とを有し、
光学機能部は、光線を屈折する作用を有する第1光学機能面と第2光学機能面を有し、
コバ部は、接続部と連なる傾斜部と、その他の外周部から構成され、光軸を含む光学素子断面は、
第1光学機能面側と第2光学機能面側のそれぞれの傾斜部は、接続部側から外周部に向けて光学素子の光軸方向の厚みが厚くなるような傾斜角を有し、
光学機能部と接続部が圧縮成形材を圧縮成形して形成され、コバ部は、主に、射出成形により形成され、コバ部内に、射出成形材料と、圧縮成形材料が接続部からコバ部に向けてはみ出したはみ出し部とによる境界面が形成されており、はみだし部の断面を、接続部の厚みを二等分する光軸に垂直な垂直二等分線で分割し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、はみ出した圧縮成形材料の断面積の60%以上となるようにはみだし部が片寄せされている光学素子。
ここでは、光学素子の一例であるプラスチックレンズを第1の金型と第2の金型からなる一対の成形用金型の間で成形加工する場合を説明する。光学素子の製造工程は、球形もしくは光学機能部の最終形状に近い形状に予め形成されたプリフォームを圧縮成形する圧縮成形工程と、その後にレンズ外周部にコバ部を射出成形により成形する射出成形工程との2段階の工程を有する。
図1は本発明の実施形態を説明するための図で、光学素子としての光学素子を成形する成形用金型の模式的な断面図である。
成形用金型11は、第1の金型13と第2の金型15を備える。図1に示す状態は、圧縮成形材料M1を第2の金型15に載置した状態である。ここで、圧縮成形材料M1は、熱可塑性と透光性を有する合成樹脂材料からなるプリフォームである。
互いに対向して配置される第1転写面21と第2転写面23との間で、光学素子成形用キャビティとなるキャビティ25が形成される。キャビティ25は、第1光学機能部転写面21aと第2光学機能部転写面23aとの間で形成される光学機能部成形用キャビティ27と、光学機能部成形用キャビティ27の外周縁に接続される第1接続部転写面外周部転写面21bと第2接続部外周部転写面23bとの間で形成される環状の接続部成形用キャビティ28と、第1の傾斜部転写面21cとそれに連なる第1外周部転写面21dと第2傾斜部転写面23cとそれに連なる第2外周部転写面23dから形成されるコバ部成形用キャビティ29とを有する。
圧縮成形工程では、まず、図3(A)に示すように、第1の金型13と第2の金型15とが近接するように両者を相対移動させる。そして、第1の金型13の第1光学機能部転写面21aと第2の金型15の第2光学機能部転写面23aとの間で、ガラス転移温度以上に加熱された圧縮成形材料M1を押圧する。これにより、圧縮成形材料M1に表裏一対の光学機能面の形状が転写される。
はみ出し部の面積が60%未満の場合、片寄せ効果が十分に確保できずに、射出成形用樹脂の流路を安定して確保しようとすると、光学素子の外径を大きくする必要があるため、空間効率を高くすることが困難となる。結果、接続部成形用キャビティからコバ部成形用キャビティにはみ出した圧縮成形材料M1の外周縁部の形状が不安定となってしまうか可能性がある。
射出成形工程は、第1の金型13と第2の金型15を型閉した状態のままで行われる。図5(A)に示すように、射出成形材料M2を、第1の金型13に設けた射出ゲート55から第1外周部転写面21dと第2外周部転写面23dとの間で区画されるコバ部成形用キャビティ29に射出する。このコバ部成形用キャビティ29は、圧縮成形材料M1の外周側で環状に形成される。射出成形材料M2は、圧縮成形工程において第1の金型13と第2の金型15とを型閉した後、圧縮成形材料M1の温度がガラス転移温度以下になる前に射出成形用キャビティ29に射出される。即ち、圧縮成形材料M1が半固形状態のうちに射出成形材料M2をコバ部成形用キャビティ29に供給することにより、圧縮成形材料M1と射出成形材料M2の密着力が強化できる。
すなわち、第1の金型の光学素子の外形部の側端面を転写する第1側端転写面100の抜き勾配が第2の金型の外形部を転写する第2側端転写面101の抜き勾配よりも小さくなっていることから、第1側端転写面100側の離型抵抗が大きくなり、結果として成形品は型開の際に第1の金型側に保持されることとなる。
このように、上記工程を採用することにより、射出成形側の離型抵抗を自由に調整できるようになることから、成型品を確実に一方の型に残すことが可能になる。
射出ゲート55からコバ部成形用キャビティ29に注入される射出成形材料は、コバ部成形用キャビティ29を図中P1,P2方向に分岐して流動する。はみ出し部47は、プリフォームの中心がずれた側がはみ出し量が最も多い最大ははみ出し位置Zとなる、その反対側は少ない。従って、射出成形材料の流路は、P2方向よりP1方向で流路が狭くなる傾向になる。
なお、圧縮成形用樹脂は、透光性を有する合成樹脂が望ましい。
本発明のような光学素子は、反射面としてではなく、主に光の屈折作用を得る目的で利用される。特に所定の結像性能を得るためには複数枚の光学素子を組み合わせることが行われることから、光学素子には高い透光性が望まれる。光学素子の透光性は高いほど好ましいが、厚さ1mmあたりの内部透過率が70%以上であれば広い用途に利用可能であり、更に好ましい。反対に、光学素子の厚さ1mmあたりの内部透過率が70%以下の場合は、光量ロスが大きくなることから、用途が制限されてしまう可能性がある。
次に、コバ部成形用キャビティの接続部成形用キャビティとの接続部分に対応する傾斜部転写面の傾斜角を変更することにより、はみ出し部のはみ出し方向を偏向させる他の例を説明する。
図8は成形金型における接続部成形用キャビティとコバ部成形用キャビティの断面図であり、第1の金型13Bと第2の金型15Bを備える。
本構成例では、端部S2とS5が型閉め方向(光軸方向)に重なっている。また、第1の金型13Bの端部S2から外周側に接続される第1傾斜部転写面31の傾斜方向と、図2に示した光学素子の光軸Ax(型閉め方向と同義)との成す角をθ1とし、第2の金型15Bの端部S5から外周側に接続される第2傾斜部転写面の傾斜方向と、型閉め方向との成す角をθ2としたとき、θ1>θ2の関係を有する。
なお、図6では、プリフォームのずれ方向を最大はみ出し位置をZとしているが、Zの位置はこれに限定されるものではなく、はみ出した圧縮成形材料M1の断面積が最大になる部分が最大はみ出し位置をZとするものである。
このように、コバ部整形用キャビティの中で、接続部成形用キャビティからはみ出したはみ出し部を、任意の方向に片寄せするための手段は複数可能であって、目的の範囲内で自由に組合せが可能である。
なお、ウェルドラインWLは、ゲートから射出された樹脂が射出成形キャビティで2分されて充填される。そして、それぞれの樹脂がキャビティ内で合流する面をウェルドラインとしている。このウェルドラインを図面では明示したが、樹脂温度や射出速度や圧力などの成形条件を制御することにより、目視にて確認できないレベルまで目立たなくすることも可能であることには留意されたい。
・着色剤により光吸収効果
・樹脂材料に、樹脂材料とは屈折率の異なる粒状物質を混入させた混合材料による光拡散効果
・圧縮成形材料M1と射出成形材料M2の屈折率を意図的に差を持たせることによる界面の入射反射特性のコントロール等が考えられる。
また、本発明によるレンズは、薄型化と組み立て適性等の向上が両立可能なことから、携帯電話やスマートフォン等に用いられる小型かつ薄形のレンズモジュールに好適な光学素子が提供することが可能となる。
これらを本発明に適用することも可能である。
(1)一対の成形用金型はそれぞれ、光学機能部を形成するための光学機能部転写面と、光学機能面の外周部に連なる接続部を形成するための接続部転写面と、接続部転写面の外周部に連なる傾斜部を形成するための傾斜部転写面と傾斜部転写面に連なる外周部を形成するための外周部転写面を有し、
一対の成形用金型は型閉時に、光学機能部転写面で形成される光学機能部成形用キャビティと、接続部転写面で形成される接続部成形用キャビティと、傾斜部転写面と傾斜部転写面に連なる外周部転写面で形成されるコバ部成形用キャビティで形成されるキャビティを有し、第1の金型と第2の金型の傾斜部転写面は、それぞれ、接続部転写面側から外周部転写面側に向かって光学素子の光軸方向の厚みが、厚くなるように拡開する傾斜角を有し、一対の成形用金型の一方の金型の光学機能部転写面に光学素子の体積よりも小さな体積の圧縮成形材料を投入し、型を閉じながら圧縮成形材料を押し広げて成形用金型の光学機能部転写面と接続部転写面の形状を圧縮成形材料に転写するとともに、圧縮成形材料の一部を接続部成形用キャビティからコバ部成形用キャビティ側に膨出したはみ出し部を形成する圧縮成形工程と、
一対の成形用金型の型が閉じた状態でコバ部成形用キャビティに溶融した射出成形材料を充填して、圧縮成形された圧縮成形材料の外周に射出成形部を形成する射出成形工程と、
を有し、
接続部成形用キャビティの光軸方向の厚みを二等分する光軸に垂直な垂直二等分線で、接続部成形用キャビティからコバ部成形用キャビティにはみ出したはみ出し部の断面形状を二分し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、はみ出した圧縮成形材料の断面積の60%以上となるように、はみ出し部がHS1の金型側に片寄せされている光学素子の製造方法。
(2) (1)の光学素子の製造方法であって、
成形用金型のコバ部成形用キャビティを形成する傾斜部転写面が、圧縮成形材料が接続部成形用キャビティからコバ部成形用キャビティに光軸方向に広がりながら膨出してはみ出す際に、第1の金型側と第2の金型側を流れる樹脂の圧縮成形材料の各広がり方向に対して流動速度差を発生させる形状にする光学素子の製造方法。
(3) (1)又は(2)の光学素子の製造方法であって、
第1の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向の距離を第1境界位置半径、第2の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向の距離を第2境界位置半径としたとき、第1境界位置半径と第2境界位置半径の小さな値の境界位置を有する金型側にはみだした樹脂を片寄せする光学素子の成形方法
(4) (1)~(3)のいずれか一つの光学素子の製造方法であって、
第1の金型側の傾斜部転写面と光軸とのなす傾斜角の絶対値をθ1、第2の金型側の傾斜部転写面と光軸のなす傾斜角の絶対値をθ2としたとき、θ1とθ2が異なる角度であって、傾斜角の絶対値の小さな角度を有する金型側にはみだした樹脂を片寄せする光学素子の成形方法。
(5) (1)~(4)のいずれか一つの光学素子の製造方法であって、
光学素子の成形用キャビティの光軸方向の厚みの最も薄い部分を、光学機能部成形用キャビティもしくは接続部成形用キャビティに有する光学素子の製造方法。
(6) (1)~(5)のいずれか一つの光学素子の製造方法であって、
圧縮成形工程は、圧縮成形材料をガラス転移温度以上に加熱して行い、
射出成形工程は、圧縮成形後の圧縮成形材料がガラス転移温度以上の状態で射出成形を開始する光学素子の製造方法。
(7) (1)~(6)のいずれか一つの光学素子の製造方法であって、
圧縮成形材料は、厚さが1mmあたり70%以上の内部透過率を有する透光性を有する合成樹脂である光学素子の製造方法。
(8) (7)の光学素子の製造方法であって、
圧縮成形材料は、光学素子に近い形状に予め形成されたプリフォームである光学素子の製造方法。
(9) (1)~(8)のいずれか一つの光学素子の製造方法であって、
光学素子は、レンズを含んで構成される光学素子の製造方法。
(10) 第1の金型と第2の金型からなる一対の成形用金型により光学素子を成形加工する光学素子の製造装置であって、
一対の成形用金型はそれぞれ、光学機能部を形成するための光学機能部転写面と、光学機能面の外周部に連なる接続部を形成するための接続部転写面と、接続部転写面の外周部に連なる傾斜部を形成するための傾斜部転写面と傾斜部転写面に連なる外周部を形成するための外周部転写面を有し、
一対の成形用金型は型閉時に、光学機能部転写面で形成される光学機能部成形用キャビティと、接続部転写面で形成される接続部成形用キャビティと、傾斜部転写面と傾斜部転写面に連なる外周部転写面で形成されるコバ部成形用キャビティで形成されるキャビティを有し、
第1の金型と第2の金型の傾斜部転写面は、それぞれ、接続部転写面側から外周部転写面側に向かって光学素子の光軸方向の厚みが、厚くなるように拡開する傾斜角を有し、
一対の成形用金型の一方の金型の光学機能部転写面に光学素子の体積よりも小さな体積の圧縮成形材料を投入し、型を閉じながら圧縮成形材料を押し広げて成形用金型の光学機能部転写面と接続部転写面の形状を圧縮成形材料に転写するとともに、圧縮成形材料の一部を接続部成形用キャビティからコバ部成形用キャビティ側に膨出したはみ出し部を形成する圧縮成形工程と、
一対の成形用金型の型が閉じた状態でコバ部成形用キャビティに溶融した射出成形材料を充填して、圧縮成形された圧縮成形材料の外周に射出成形部を形成する射出成形工程と、を有し、
接続部成形用キャビティの光軸方向の厚みを二等分する光軸に垂直な垂直二等分線で、接続部成形用キャビティからコバ部成形用キャビティにはみ出した圧縮成形材料の断面形状を二分し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、はみ出した圧縮成形材料の断面積の60%以上となるように、はみ出し部が片寄せされている光学素子の製造装置。
(11) (10)の光学素子の製造装置であって、
成形用金型のコバ部成形用キャビティを形成する傾斜部転写面が、圧縮成形材料が接続部成形用キャビティからコバ部成形用キャビティに光軸方向に広がりながら膨出してはみ出す際に、第1の金型側と第2の金型側を流れる樹脂の圧縮成形材料の各広がり方向に対して流動速度差を発生させる形状にする光学素子の製造方法。
(12) (10)又は(11)の光学素子の製造装置であって、
第1の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向の距離を第1境界位置半径、第2の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向距離を第2境界位置半径としたとき、第1境界位置半径と第2境界位置半径の小さな値を有する金型側にはみだした樹脂を片寄せする
光学素子の製造装置。
(13) (10)~(12)のいずれか一つの光学素子の製造装置であって、
第1の金型側の傾斜部転写面と光軸とのなす傾斜角の絶対値をθ1、第2の金型側の傾斜部転写面と光軸のなす傾斜角の絶対値をθ2としたとき、θ1とθ2が異なる角度であって、傾斜角の絶対値が小さい角度を有する金型側にはみだした樹脂を片寄せする
光学素子の製造装置。
(14) 中心を光軸とする円状の光学機能部と、光学機能部の外周縁に環状に形成された接続部と、接続部の外周縁に環状に形成されたコバ部とを有し、
光学機能部は、光線を屈折する作用を有する第1光学機能面と第2光学機能面を有し、
コバ部は、接続部と連なる傾斜部と、その他の外周部から構成され、光軸を含む光学素子断面は、
第1光学機能面側と第2光学機能面側のそれぞれの傾斜部は、接続部側から外周部に向けて光学素子の光軸方向の厚みが厚くなるような傾斜角を有し、
光学機能部と接続部が圧縮成形材を圧縮成形して形成され、コバ部は、主に、射出成形により形成され、コバ部内に、射出成形材料と、圧縮成形材料が接続部からコバ部に向けてはみ出したはみ出し部とによる境界面が形成されており、はみだし部の断面を、接続部の厚みを二等分する光軸に垂直な垂直二等分線で分割し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、はみ出した圧縮成形材料の断面積の60%以上となるように片寄せされている光学素子。
(15) (14)の光学素子であって、
光学素子断面において、第1光学機能面を有する側を第1の側、第2光学機能面を有する側を第2の側とするとき、第1の側の接続部の接続面とコバ部の傾斜面との境界点と、第2の側の接続部の接続面とコバ部の傾斜面との境界点は、接続部からはみだした樹脂を片寄せしている側の境界点の方が光軸からの径方向の距離が近い光学素子。
(16) (14)の光学素子であって、
光学素子断面において、第1光学機能面を有する側を第1の側、第2光学機能面を有する側を第2の側とするとき、第1面側のコバ部の傾斜部と第2、面側の傾斜部の光軸に対する傾斜角の絶対値は、はみだした樹脂を片寄せしている側が小さい光学素子。
(17) (14)~(16)のいずれか一つの光学素子を
少なくとも1枚含む、レンズモジュール。
13 第1の金型
15 第2の金型
21 第1転写面
21a 第1光学機能部転写面
21b 接続部転写面
21c 第1傾斜部転写面
21d 第1外周部転写面
23 第2転写面
23a 第2光学機能部転写面
23b 第2外周部転写面
23c 第2傾斜部転写面
23d 第2外周部転写面
25 キャビティ
27 光学機能部成形用キャビティ
28 接続部成形用キャビティ
29 コバ部成形用キャビティ
45 膨出端
47 はみ出し部
51 光学機能部
53 接続部
57 界面
59 光学素子
61 コバ部
S2,S5 端部
Ax レンズ光軸
L 光軸に垂直な垂直二等分線
O 光軸位置
G はみ出しマージン寸法
Z 最大はみ出し位置
Claims (17)
- 第1の金型と第2の金型からなる一対の成形用金型を用いる成形加工によって光学素子を得る光学素子の製造方法であって、
前記一対の成形用金型はそれぞれ、光学機能部を形成するための光学機能部転写面と、前記光学機能面の外周部に連なる接続部を形成するための接続部転写面と、前記接続部転写面の外周部に連なる傾斜部を形成するための傾斜部転写面と前記傾斜部転写面に連なる外周部を形成するための外周部転写面を有し、
前記一対の成形用金型は型閉時に、光学機能部転写面で形成される光学機能部成形用キャビティと、前記接続部転写面で形成される接続部成形用キャビティと、前記傾斜部転写面と傾斜部転写面に連なる外周部転写面で形成されるコバ部成形用キャビティで形成されるキャビティを有し、
前記第1の金型と前記第2の金型の傾斜部転写面は、それぞれ、前記接続部転写面側から前記外周部転写面側に向かって前記光学素子の光軸方向の厚みが、厚くなるように拡開する傾斜角を有し、
前記一対の成形用金型の一方の金型の前記光学機能部転写面に前記光学素子の体積よりも小さな体積の圧縮成形材料を投入し、型を閉じながら前記圧縮成形材料を押し広げて前記成形用金型の光学機能部転写面と接続部転写面の形状を前記圧縮成形材料に転写するとともに、前記圧縮成形材料の一部を前記接続部成形用キャビティからコバ部成形用キャビティ側に膨出したはみ出し部を形成する圧縮成形工程と、
前記一対の成形用金型の型が閉じた状態で前記コバ部成形用キャビティに溶融した射出成形材料を充填して、圧縮成形された前記圧縮成形材料の外周に射出成形部を形成する射出成形工程と、を有し、
前記接続部成形用キャビティの光軸方向の厚みを二等分する光軸に垂直な垂直二等分線で、前記接続部成形用キャビティからコバ部成形用キャビティにはみ出したはみ出し部の断面形状を二分し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、前記はみ出した圧縮成形材料の断面積の60%以上となるように、はみ出し部がHS1の金型側に片寄せされている、光学素子の製造方法。 - 請求項1記載の光学素子の製造方法であって、
前記成形用金型の前記コバ部成形用キャビティを形成する傾斜部転写面が、前記圧縮成形材料が前記接続部成形用キャビティから前記コバ部成形用キャビティに光軸方向に広がりながら膨出してはみ出す際に、第1の金型側と第2の金型側を流れる樹脂の前記圧縮成形材料の各広がり方向に対して流動速度差を発生させる形状にする、光学素子の製造方法。 - 請求項1又は請求項2記載の光学素子の製造方法であって、
前記第1の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向の距離を第1境界位置半径、前記第2の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向の距離を第2境界位置半径としたとき、前記第1境界位置半径と前記第2境界位置半径の小さな値の境界位置を有する金型側に前記はみだした樹脂を片寄せする、光学素子の成形方法 - 請求項1~請求項3のいずれか一項記載の光学素子の製造方法であって、
前記第1の金型側の傾斜部転写面と光軸とのなす傾斜角の絶対値をθ1、前記第2の金型側の傾斜部転写面と光軸のなす傾斜角の絶対値をθ2としたとき、θ1とθ2が異なる角度であって、前記傾斜角の絶対値の小さな角度を有する金型側に前記はみだした樹脂を片寄せする、光学素子の成形方法。 - 請求項1~請求項4のいずれか一項記載の光学素子の製造方法であって、
前記光学素子の成形用キャビティの光軸方向の厚みの最も薄い部分を、前記光学機能部成形用キャビティもしくは前記接続部成形用キャビティに有する、光学素子の製造方法。 - 請求項1~請求項5のいずれか一項記載の光学素子の製造方法であって、
前記圧縮成形工程は、前記圧縮成形材料をガラス転移温度以上に加熱して行い、
前記射出成形工程は、前記圧縮成形後の前記圧縮成形材料がガラス転移温度以上の状態で射出成形を開始する、光学素子の製造方法。 - 請求項1~請求項6のいずれか一項記載の光学素子の製造方法であって、
前記圧縮成形材料は、厚さが1mmあたり70%以上の内部透過率を有する透光性を有する合成樹脂である、光学素子の製造方法。 - 請求項7記載の光学素子の製造方法であって、
前記圧縮成形材料は、前記光学素子に近い形状に予め形成されたプリフォームである、光学素子の製造方法。 - 請求項1~請求項8のいずれか一項記載の光学素子の製造方法であって、
前記光学素子は、レンズを含んで構成される、光学素子の製造方法。 - 第1の金型と第2の金型からなる一対の成形用金型により光学素子を成形加工する光学素子の製造装置であって、
前記一対の成形用金型はそれぞれ、光学機能部を形成するための光学機能部転写面と、前記光学機能面の外周部に連なる接続部を形成するための接続部転写面と、前記接続部転写面の外周部に連なる傾斜部を形成するための傾斜部転写面と前記傾斜部転写面に連なる外周部を形成するための外周部転写面を有し、
前記一対の成形用金型は型閉時に、光学機能部転写面で形成される光学機能部成形用キャビティと、前記接続部転写面で形成される接続部成形用キャビティと、前記傾斜部転写面と傾斜部転写面に連なる外周部転写面で形成されるコバ部成形用キャビティで形成されるキャビティを有し、
前記第1の金型と前記第2の金型の傾斜部転写面は、それぞれ、接続部転写面側から外周部転写面側に向かって前記光学素子の光軸方向の厚みが、厚くなるように拡開する傾斜角を有し、
前記一対の成形用金型の一方の金型の前記光学機能部転写面に前記光学素子の体積よりも小さな体積の圧縮成形材料を投入し、型を閉じながら前記圧縮成形材料を押し広げて前記成形用金型の光学機能部転写面と接続部転写面の形状を前記圧縮成形材料に転写するとともに、前記圧縮成形材料の一部を前記接続部成形用キャビティからコバ部成形用キャビティ側に膨出したはみ出し部を形成する圧縮成形工程と、
前記一対の成形用金型の型が閉じた状態で前記コバ部成形用キャビティに溶融した射出成形材料を充填して、圧縮成形された前記圧縮成形材料の外周に射出成形部を形成する射出成形工程と、を有し、
前記接続部成形用キャビティの光軸方向の厚みを二等分する光軸に垂直な垂直二等分線で、前記接続部成形用キャビティからコバ部成形用キャビティにはみ出した前記圧縮成形材料の断面形状を二分し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、HS1の面積が、前記はみ出した圧縮成形材料の断面積の60%以上となるように、はみ出し部が片寄せされている、光学素子の製造装置。 - 請求項10記載の光学素子の製造装置であって、
前記成形用金型の前記コバ部成形用キャビティを形成する傾斜部転写面が、前記圧縮成形材料が前記接続部成形用キャビティから前記コバ部成形用キャビティに光軸方向に広がりながら膨出してはみ出す際に、第1の金型側と第2の金型側を流れる樹脂の前記圧縮成形材料の各広がり方向に対して流動速度差を発生させる形状にする、光学素子の製造装置。 - 請求項10又は請求項11記載の光学素子の製造装置であって、
前記第1の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向の距離を第1境界位置半径、前記第2の金型の接続部転写面と傾斜部転写面の境界位置から光軸までの径方向距離を第2境界位置半径としたとき、前記第1境界位置半径と前記第2境界位置半径の小さな値を有する金型側に前記はみだした樹脂を片寄せする、光学素子の製造装置。 - 請求項10~請求項12のいずれか一項記載の光学素子の製造装置であって、
前記第1の金型側の傾斜部転写面と光軸とのなす傾斜角の絶対値をθ1、前記第2の金型側の傾斜部転写面と光軸のなす傾斜角の絶対値をθ2としたとき、θ1とθ2が異なる角度であって、前記傾斜角の絶対値が小さい角度を有する金型側に前記はみだした樹脂を片寄せする、光学素子の製造装置。 - 中心を光軸とする円状の光学機能部と、前記光学機能部の外周縁に環状に形成された接続部と、前記接続部の外周縁に環状に形成されたコバ部とを有し、
前記光学機能部は、光線を屈折する作用を有する第1光学機能面と第2光学機能面を有し、
前記コバ部は、前記接続部と連なる傾斜部と、その他の外周部から構成され、
前記光軸を含む光学素子断面は、
前記第1光学機能面側と前記第2光学機能面側のそれぞれの前記傾斜部は、前記接続部側から前記外周部に向けて光学素子の光軸方向の厚みが厚くなるような傾斜角を有し、
前記光学機能部と前記接続部が圧縮成形材を圧縮成形して形成され、前記コバ部は、主に、射出成形により形成され、前記コバ部内に、射出成形材料と、圧縮成形材料が前記接続部からコバ部に向けてはみ出したはみ出し部とによる境界面が形成されており、前記はみだし部の断面を、前記接続部の厚みを二等分する光軸に垂直な垂直二等分線で分割し、面積の大きい側をHS1、面積の小さい側をHS2としたときに、前記HS1の面積が、前記はみ出した圧縮成形材料の断面積の60%以上となるように片寄せされている、光学素子。 - 請求項14の光学素子であって、
前記光学素子断面において、前記第1光学機能面を有する側を第1の側、前記第2光学機能面を有する側を第2の側とするとき、前記第1の側の接続部の接続面と前記コバ部の傾斜面との境界点と、前記第2の側の接続部の接続面と前記コバ部の傾斜面との境界点は、前記接続部からはみだした樹脂を片寄せしている側の境界点の方が光軸からの径方向の距離が近い、光学素子。 - 請求項14の光学素子であって、
前記光学素子断面において、前記第1光学機能面を有する側を第1の側、前記第2光学機能面を有する側を第2の側とするとき、前記第1面側のコバ部の傾斜部と第2、面側の傾斜部の前記光軸に対する傾斜角の絶対値は、前記はみだした樹脂を片寄せしている側が小さい、光学素子。 - 請求項14~請求項16のいずれか一項記載の光学素子を少なくとも1枚含む、レンズモジュール。
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