WO2014199767A1 - Optical element manufacturing method - Google Patents
Optical element manufacturing method Download PDFInfo
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- WO2014199767A1 WO2014199767A1 PCT/JP2014/062795 JP2014062795W WO2014199767A1 WO 2014199767 A1 WO2014199767 A1 WO 2014199767A1 JP 2014062795 W JP2014062795 W JP 2014062795W WO 2014199767 A1 WO2014199767 A1 WO 2014199767A1
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- WIPO (PCT)
- Prior art keywords
- mold
- optical element
- optical
- transfer surface
- positioning portion
- Prior art date
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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
- B29D11/005—Moulds for lenses having means for aligning the front and back moulds
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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
- B29C43/02—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
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/04—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles using movable moulds
- B29C43/06—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles using movable moulds continuously movable in one direction, e.g. mounted on chains, belts
- B29C43/08—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles using movable moulds continuously movable in one direction, e.g. mounted on chains, belts with circular movement, e.g. mounted on rolls, turntables
Definitions
- the present invention relates to a method for manufacturing an optical element suitable for mass production of optical elements.
- optical elements used in optical pickup devices, imaging devices, etc. require high precision, but in recent years, competition with overseas manufacturers has intensified, and in order to increase the competitiveness of products, costs can be further reduced. It is requested to do.
- Patent Document 1 discloses a molding apparatus that coaxially positions a first mold and a second mold using a cylindrical sleeve in molding an optical element using an energy curable resin.
- An object of the present invention has been made in view of the above-described problems, and is to provide an optical element manufacturing method capable of forming a highly accurate optical element using an energy curable resin.
- a method for manufacturing an optical element reflecting one aspect of the present invention includes the following.
- a first optical surface transfer surface for transferring the first optical surface of the optical element and a first flange surface formed around the first optical surface of the optical element are transferred to the first mold.
- the second mold includes a second optical surface transfer surface for transferring the second optical surface of the optical element, and a second flange surface transfer surface formed around the second optical surface of the optical element.
- a second positioning portion, and the second flange surface transfer surface is formed between the second positioning portion and the second optical surface transfer surface,
- a step of positioning the molds by fitting the first positioning part and the second positioning part during clamping of the first mold and the second mold; Energy is applied to an energy curable resin filled in a cavity surrounded by the first optical transfer surface and the first flange surface transfer surface, and the second optical transfer surface and the second flange surface transfer surface. And a step of curing the energy curable resin.
- energy curable resins generally have a low viscosity before curing, unlike injection molding in which a thermoplastic resin is injected into a cavity at a high pressure, high pressure does not occur in the cavity. It can be made of materials and the molding equipment can be simplified.
- resin or glass is used as the material of the mold, the shape of the mother transfer surface can be accurately transferred to the mold using, for example, the mother mold. Accordingly, the positional accuracy between the first optical surface transfer surface and the first positioning portion is ensured and / or the positional accuracy between the second optical surface transfer surface and the second positioning portion is ensured.
- the eccentricity between the first optical surface transfer surface and the second optical surface transfer surface can be suppressed.
- the coaxiality of the first optical surface and the second optical surface in the optical element formed by the first mold and the second mold can be ensured.
- a first flange surface transfer surface is formed between the first positioning portion and the first optical surface transfer surface, 2 Since the second flange surface transfer surface is formed between the positioning portion and the second optical surface transfer surface, it becomes difficult to transmit the influence of the deformation of the first positioning portion to the first optical surface transfer surface. 2 It becomes difficult to transmit the influence of the deformation of the positioning portion to the second optical surface transfer surface, whereby high-precision molding can be performed.
- an optical element manufacturing method capable of forming a highly accurate optical element using an energy curable resin.
- FIG. 1 It is a perspective view which shows the manufacturing apparatus of the optical element in this embodiment. It is a figure which expand
- A) is a figure which shows 1st type
- (C) is a diagram showing the first mold part MD1a and the second mold member MD2b after mold clamping.
- FIG. 8 It is sectional drawing which shows an example of the optical element OE manufactured by the manufacturing apparatus of this Embodiment.
- (A)-(e) is a figure which shows the process of shape
- (A)-(c) is a figure which shows the modification of a positioning part. It is a perspective view which expands and shows 1st type
- the optical element manufactured in the present invention, there are a mirror for projector and an optical element for illumination in addition to the optical element for imaging.
- the optical element is not limited to a lens, but when it is a lens, for example, it may be a flange-integrated type or a flange-separated type. Further, an integrated lens having a plurality of optical axes may be used.
- Various forms are conceivable as the lens shape, and include, for example, a convex lens, a concave lens, a thin lens, a decentered lens, a Fresnel lens, and a diffractive lens.
- the thickness of the thinnest part of the lens is particularly preferably 0.05 to 0.3 mm, and the thickness of the thinnest part of the lens is 0.05 to 0.15 mm. More preferably.
- the carrier When a “carrier” is used to transport a molded optical element, the carrier is a combination of a plurality of carrier pieces having openings, and preferably the connected carrier pieces pivot. A closed loop shape may be used, or a shape having both ends may be wound around a roll or the like.
- the carrier piece is preferably plate-like and can be formed from a material such as plastic, glass, ceramic or the like.
- the opening of the carrier piece is preferably shaped to mold the outer periphery of the optical element. Preferably, a step is formed in the opening.
- At least one of the first mold and the second mold is made of resin or glass.
- Resins include thermoplastic resins that can be molded in large quantities and low cost, and energy curable resins. When glass is used as the material, there is an effect that the positioning portion is hardly deteriorated and the durability is excellent.
- the other of the first mold and the second mold can be formed from a metal or ceramic in addition to resin or glass.
- the first mold includes a first optical surface transfer surface that transfers the first optical surface of the optical element, and a first flange surface that transfers the first flange surface formed around the first optical surface of the optical element. It has a transfer surface and a first positioning part. A first flange surface transfer surface is formed between the first positioning portion and the first optical surface transfer surface.
- the second mold includes a second optical surface transfer surface for transferring the second optical surface of the optical element, a second flange surface transfer surface formed around the second optical surface of the optical element, and a second positioning. Part. A second flange surface transfer surface is formed between the second positioning portion and the second optical surface transfer surface.
- a mold made of resin or glass (hereinafter referred to as a specific mold) is preferably transferred and molded from a mother mold because a high-precision specific mold can be mass-produced.
- the mother die is preferably formed by machining or the like using a metal as a raw material.
- the mother optical surface transfer surface for transferring the specific type optical surface transfer surface and the mother positioning portion transfer surface for transferring the specific type positioning portion are machined on the same axis.
- the mother optical surface transfer surface may be free-form surface processing.
- the energy curable resin is a photocurable resin
- the specific mold is formed of a material that transmits light.
- it is not a specific type it is not always necessary to transmit light.
- the first mold and the second mold may be formed from one member, or may be formed by combining a plurality of members.
- one mold is formed from one member, and the other mold is a combination of a plurality of members.
- One of the first positioning portion and the second positioning portion may have a cylindrical inner peripheral surface shape, and the other may have a cylindrical outer peripheral surface shape. Thereby, positioning accuracy can be secured. Further, one of the first positioning portion and the second positioning portion may have a conical tapered inner peripheral surface shape, and the other may have a conical tapered outer peripheral surface shape. Thereby, mold clamping can be performed smoothly. Further, one of the first positioning portion and the second positioning portion may have a cylindrical inner peripheral surface shape, and the other may have a conical tapered outer peripheral surface shape. It is preferable to provide a chamfered portion in at least one of the first positioning portion and the second positioning portion because guidance during fitting can be performed. When the positioning portions are not continuous, it is preferable to provide two or more locations.
- the first mold and the second mold can be positioned with high accuracy.
- the maximum clearance in the direction perpendicular to the axis of the first positioning portion and the second positioning portion is adjusted to be more than 0 ⁇ m and 10 ⁇ m or less, the fitting can be performed smoothly.
- the axial thickness of the optical element to be molded can be accurately set.
- the axial thickness of the optical element to be molded can be adjusted by interposing a shim having an appropriate thickness in the abutting portion.
- the holding means for holding at least one of the first die and the second die so as to be relatively movable in a direction intersecting the axis of the one die, the first positioning portion and the second positioning portion are fitted. At the time, centering is performed by the function of the holding means, and the fitting can be realized smoothly.
- the holding means an air slider, an elastic body such as rubber or a spring, a magnet, or the like can be used.
- the first mold and the second mold may have not only a transfer surface for molding a single optical element but also a transfer surface for molding a plurality of optical elements.
- the mold may be formed with a structure such as fine irregularities or a water-repellent film.
- Examples of the “energy curable resin” that can be used in the present invention include a photocurable resin and a thermosetting resin.
- the mold material is PET (polyethylene terephthalate) resin, PMMA (polymethyl methacrylate) resin, COC (cycloolefin copolymer) resin, COP (cycloolefin polymer) resin, PC (polycarbonate) resin, fluorine.
- a thermoplastic resin such as a resin, a photocurable resin such as an epoxy resin, an acrylic resin, or a vinyl resin, or glass can be used. Glass can be produced by glass molding, droplet molding, reheating molding, or the like.
- the mold material it is preferable to use a material that easily transmits a wavelength for curing a photocurable resin used as a material of the optical element.
- the energy curable resin When supplying the energy curable resin with the first mold and the second mold open, the energy curable resin may be supplied to any mold, but when using a dispenser or the like, the mold is located below the gravitational direction. It is desirable to supply.
- the mold to which the energy curable resin is supplied may be rotated, and the energy curable resin may be spread on the transfer surface of the mold by centrifugal force.
- the energy curable resin can be supplied after the first mold and the second mold are clamped as in, for example, injection molding.
- energy can also be imparted to the energy curable resin while clamping the first mold and the second mold.
- Such energy application can be performed from one or both of the first mold and the second mold.
- a structure for projecting the molded optical element with a core or a pin or a structure for applying ultrasonic vibration to the mold may be provided as a mold release assisting structure.
- various forms such as an air chuck, a robot chuck, and air blowing can be used.
- various pre-molding processes for performing pre-processing before molding may be performed.
- a camera is used to monitor whether there is an abnormality in the mold, and if there is an abnormality, a process for stopping the production of the optical element by issuing an alarm, or a process for cleaning the mold used for molding
- a process silicon coating
- a post-molding process for performing post-molding post-processing may be performed in the fourth processing unit that performs the process of taking out the molded optical element.
- the post-molding process include a post-cure for heating and the like, and a process for annealing in order to completely cure the molded optical element.
- first mold and second mold and the subsequent first mold and second mold are arranged at equal intervals and move at a constant speed.
- the interval between the molds may be locally changed for timing adjustment.
- the “closed locus” refers to the first processing unit from the first processing unit to the second processing unit, the third processing unit, and the fourth processing unit in order, regardless of the shape. This means that the movement trajectories of the first mold and the second mold until reaching the part are closed loops.
- a branch may be provided in the movement trajectory in order to eliminate abnormal molds, or another route that is coupled to a closed trajectory may be provided in order to insert a non-abnormal mold that has been waiting.
- FIG. 1 is a perspective view showing a manufacturing apparatus capable of executing the method of manufacturing an optical element in the present embodiment.
- FIG. 2 is a diagram showing the optical element manufacturing apparatus of FIG. 1 developed in the circumferential direction.
- the manufacturing apparatus arranges the first disk DC1 as the first holding body and the second disk DC2 as the second holding body coaxially with a gap therebetween. Yes.
- the center of the first disk DC1 and the second disk DC2 is connected to the rotation shaft SFT through a spline or the like so as not to rotate relative to the rotation shaft SFT.
- the first disk DC1 and the second disk DC2 are driven to rotate synchronously.
- a plurality of circular openings DC1a are formed in the first disk DC1, and a cylindrical upper mold MD1 is fixed in the circular opening DC1a.
- the upper mold MD1 has a first mold part MD1a attached to the lower surface.
- the upper mold MD1 and the first mold part MD1a are made of resin or glass.
- the upper mold MD1 and the first mold part MD1a constitute the first mold, but these may be integrally formed.
- the second disk DC2 is formed with a plurality of (eight in this case) circular openings DC2a so as to be coaxial with the circular opening DC1a.
- a cylindrical lower mold MD2 is formed in the circular opening DC2a. It is arranged to be movable in the axial direction.
- the lower mold MD2 has a second mold part MD2a attached to the upper surface.
- the lower mold MD2 and the second mold part MD2a constitute a second mold.
- the shielding part SH is formed so as to cover a part of the first disk DC1 and the second disk DC2 in the circumferential direction.
- a plurality of light sources OPS as energy supply sources are arranged along the circumferential direction of the first disk DC1 and the second disk DC2, and the light emitting surface faces downward.
- the light source OPS is preferably provided directly above the center locus of the upper mold MD1 that rotates.
- a ring-shaped cam plate CP constituting the mold drive unit is fixedly disposed below the second disk DC2.
- the cam surface CPa of the cam plate CP has a low portion CPb, an ascending slope CPc, a high portion CPd, and a descending slope CPe according to the position in the circumferential direction.
- a wheel-shaped follower FW that rolls on the cam surface CPa and a support portion SP that rotatably supports the follower FW are formed.
- the first processing unit A, the second processing unit B, the third processing unit C, and the fourth processing unit D according to the rotational positions of the first disk DC1 and the second disk DC2. It has become.
- dispenser DSP which can discharge a suitable quantity of photocurable resin is arrange
- a light source OPS is arranged in the second processing unit B.
- an arm type robot RB for taking out the molded optical element OE is arranged.
- FIG. 3 is an enlarged view of the first mold part MD1a and the second mold part MD2a of FIG.
- the first mold part MD1a is generally disk-shaped, has a curved first optical surface transfer surface MD1b at the center, and has a flat ring-shaped first flange surface transfer around it.
- a surface MD1c is provided, and a cylindrical portion MD1d is formed around the surface MD1c.
- the inner peripheral surface MD1e of the cylindrical part MD1d constitutes a first positioning part.
- the tip of the cylindrical portion MD1d is a flat abutting surface MD1f, and a tapered surface MD1g as a chamfered portion is formed between the inner peripheral surface MD1e and the abutting surface MD1f.
- the second mold part MD2a holds the second mold member MD2b, the annular air slider AS fixed to the second mold MD2, the second mold member MD2b fixedly, and is floated by the air slider AS. It has a supported holder HLD.
- the second mold member MD2b is generally disk-shaped, has a second optical surface transfer surface MD2c having a curved surface at the center, and has a second flange surface transfer surface MD2d having a flat ring shape around it.
- the periphery of the second flange surface transfer surface MD2d is formed in a cylindrical shape, and the outer peripheral surface MD2e forms a second positioning portion.
- the outer side of the outer peripheral surface MD2e is a flat surface MD2f that spreads radially.
- the air slider AS is capable of floatingly supporting the holder HLD with low friction by blowing air from the surface facing the holder HLD.
- a method for manufacturing the optical element according to the present embodiment will be described.
- the manufacturing will be described focusing on a pair of upper mold MD1 and lower mold MD2.
- the actuator AC is driven by power supply from a power source (not shown) and the rotation shaft SFT is rotated, the first disk DC1 and the second disk DC2 rotate in synchronization.
- the follower FW of the lower mold MD2 is in the lower portion CPb on the cam surface CPa of the cam plate CP, and therefore, the first mold part MD1a of the upper mold MD1 and the lower mold MD2
- the second mold member MD2b is in an open state, and thus the photocurable resin PL can be dropped on the second optical surface transfer surface MD2c via the dispenser DSP.
- the upper mold MD1 and the lower mold MD2 supplied with the photocurable resin PL therebetween move by the synchronous rotation of the first disk DC1 and the second disk DC2.
- the follower FW of the lower mold MD2 rolls on the climbing slope CPc on the cam surface CPa of the cam plate CP the lower mold MD2 gradually approaches the upper mold MD1.
- the axis AX1 of the first optical surface transfer surface MD1b of the first mold part MD1a and the axis AX2 of the second optical surface transfer surface MD2c of the second mold member MD2b are shifted. Shall be.
- the slope MD1g of the cylindrical part MD1d of the first mold part MD1a first becomes the second mold member MD2b in the second mold member MD2b.
- the inclined surface MD1g receives a force of a directional component perpendicular to the axis from the outer edge P, so that the second mold member MD2b is first for each holder HLD supported by the air slider AS. Centering can be performed by moving in the direction orthogonal to the optical axis with respect to the mold part MD1a, whereby the axis lines AX1 and AX2 coincide.
- the outer peripheral surface MD2e of the second mold member MD2b is connected to the inner peripheral surface MD1e of the cylindrical portion MD1d of the first mold part MD1a. Will be fitted (see FIG. 4C).
- the upper mold MD1 and the lower mold MD2 move to the second processing unit B by the synchronous rotation of the first disk DC1 and the second disk DC2 while maintaining the mold clamping state.
- the light emitted from the light source OPS reaches the photocurable resin PL via the upper mold MD1 to cure the photocurable resin PL. Since the upper mold MD1 and the lower mold MD2 pass below the fixed light sources OPS, light is irradiated from various directions, thereby being applied into the cavities of the upper mold MD1 and the lower mold MD2. Uniform curing of the photocurable resin is ensured.
- the upper mold MD1 and the lower mold MD2 move to the third processing unit C by the synchronous rotation of the first disk DC1 and the second disk DC2.
- the follower FW of the lower mold MD2 rolls on the downward slope Cpe on the cam surface CPa of the cam plate CP, the lower mold MD2 is gradually separated from the upper mold MD1 to open the mold. Is done.
- the arm of the robot RB can be expanded and contracted to take out the molded optical element OE and transport it to another process.
- the molding has been described focusing on the pair of the upper mold MD1 and the lower mold MD2.
- the high-precision optical element OE is formed. Can be produced in large quantities.
- FIG. 5 is a cross-sectional view showing an example of the optical element OE manufactured by the manufacturing apparatus of the present embodiment.
- the first optical surface S1 of the optical element OE is transferred and formed by the first optical surface transfer surface MD1b of the first mold part MD1a, and the first flange surface FL1 of the flange portion FL is transferred by the first flange surface transfer surface MD1c.
- the outer peripheral surface FL3 of the flange portion FL is formed by transfer by the inner peripheral surface MD1e of the cylindrical portion MD1d.
- the second optical surface S2 of the optical element OE is transferred and formed by the second optical surface transfer surface MD2c of the second mold member MD1b, and the second flange surface FL2 of the flange portion FL is the second flange surface transfer surface MD2d. Is transferred and formed.
- FIG. 6 is a diagram showing a molding process of the first mold part used in the manufacturing apparatus of the present embodiment.
- a matrix MM corresponding to the first mold member is formed.
- a material such as super steel is attached to a lathe or the like, and the mother transfer surface is turned with the cutting tool T while being rotated.
- a mother optical surface transfer surface MMa, a mother flange surface transfer surface MMb, and a mother positioning portion transfer surface MMc are formed on the mother die MM.
- the mother mold MM is clamped to the end face of the separate mold MM2, and the molten thermoplastic resin HPL is supplied into the space (cavity) generated inside. Thereafter, the resin HPL is solidified by heating, and as shown in FIG. 6C, the first mold member MD1a is obtained by releasing the mother mold MM from the separate mold MM2.
- the first mold member MD1a obtained by injection molding of the resin in this way is transferred and molded by the first optical surface transfer surface MD1b transferred by the mother optical surface transfer surface MMa and the mother flange surface transfer surface MMb.
- the first flange surface transfer surface MD1c and the cylindrical portion MD1d transferred and molded by the mother positioning portion transfer surface MMc.
- mold member MD1a is attached to type
- the first mold member MD1a may be molded integrally with the mold base MD1f. Thereby, a glass base material is unnecessary and joining of type
- the first mold member MD1a may be formed using glass as a material using the mother mold MM. In this case, glass molding or glass reheat molding is used.
- FIG. 7 is a view showing a modified example of the positioning portion.
- the outer edge of the second flange surface transfer surface MD2d of the second mold member MD2b is a tapered surface MD2g with respect to the above-described embodiment.
- the inner peripheral surface of the cylindrical portion MD1d of the first mold part MD1a is a tapered surface MD1e
- the outer peripheral surface of the second mold member MD2b is a tapered surface MD2e.
- the inner peripheral surface of the cylindrical portion MD1d of the first mold part MD1a is the tapered surface MD1e, but the outer peripheral surface MD2e of the second mold member MD2b is kept cylindrical.
- the taper surface MD1e contacts the outer edge P of the second flange surface transfer surface MD2d in the second mold member MD2b.
- FIG. 8 is a perspective view of a first mold part and a second mold member according to another embodiment
- FIG. 9 is a view of the configuration of FIG. 8 taken along line IX-IX and viewed in the direction of the arrow. is there.
- a plate-like spacer SPS is disposed between the first mold part MD1a and the second mold member MD2b.
- substantially crescent-shaped protrusions MD2h are formed on both sides of the second flange surface transfer surface MD2d of the second mold member MD2b.
- the outer side surface MD2i of the protrusion MD2h is a partial cylindrical surface constituting the second positioning portion, and the inner side is a flat surface MD2j.
- Spacers SPS are provided on the second flange surface transfer surface MD2d so as to abut both sides of the flat surface MD2j.
- the spacer SPS has an opening SPSa in the center.
- the lower surface of the first mold part MD1a is recessed in the shape of a shallow dish.
- the first optical surface transfer surface MD1b and the first flange surface transfer surface MD1c are formed on the bottom surface of the first mold part MD1a.
- Notches MD1h having a width of the spacer SPS are formed on both sides in the radial direction of the MD1c.
- the outside of the cutout MD1h is a substantially crescent-shaped convex portion MD1i.
- the inner peripheral surface MD1j of the convex portion MD1i constituting the second positioning portion is a partial cylindrical surface and has the same diameter as the outer surface MD2i of the protrusion MD2h.
- the first mold part MD1a and the second mold member MD2b approach each other, and the protrusion MD2h is formed on the inner peripheral surface MD1j of the convex part MD1i.
- the axes of the first optical surface transfer surface MD1b and the second optical surface transfer surface MD2c coincide.
- the first flange surface transfer surface MD1c of the first mold part MD1a is in close contact with the upper surface of the spacer SPS. Then, by irradiating light from the first mold part MD1a side, the internal photo-curable resin is cured, and the optical element can be molded.
- the outer peripheral surface of the optical element is formed by the opening SPSa of the spacer SPS.
- the spacer SPS can also be used as a carrier for transporting the molded optical element.
- a 1st processing part B 2nd processing part C 3rd processing part D 4th processing part AC Actuator AS Air slider AX1 Axis line AX2 Axis line CP Cam plate CPa Cam surface CPb Lower part CPc Slope CPd High part Cpe Slope DC1 First disk DC1a Circular opening DC2 Second disk DC2a Circular opening DSP Dispenser FL Optical element flange portion FL1 First flange surface FL2 Second flange surface FL3 Outer surface FW Follower HLD Holder HPL Thermoplastic resin MD1 Upper mold MD1a First Mold part MD1b First optical surface transfer surface MD1c First flange surface transfer surface MD1d Cylindrical portion MD1e Tapered surface MD1e Inner peripheral surface MD1f Abutting surface MD1g Tapered surface MD1i Protruding portion MD1j Inner peripheral surface MD2 Below MD2a Second mold part MD2b Second mold member MD2c Second optical surface transfer surface MD2d Second flange surface transfer surface MD2e Tapered surface or outer
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Abstract
Description
第1の型と第2の型との間に供給されたエネルギー硬化性樹脂を用いて光学素子を成形する製造方法であって、
前記第1の型と前記第2の型の少なくとも一方は、樹脂又はガラスにより形成されており、
前記第1の型には、前記光学素子の第1の光学面を転写する第1光学面転写面と、前記光学素子における前記第1の光学面の周囲に形成される第1フランジ面を転写する第1フランジ面転写面と、第1位置決め部とを有し、前記第1位置決め部と前記第1光学面転写面との間に前記第1フランジ面転写面が形成されており、
前記第2の型には、前記光学素子の第2の光学面を転写する第2光学面転写面と、前記光学素子における前記第2の光学面の周囲に形成される第2フランジ面転写面と、第2位置決め部とを有し、前記第2位置決め部と前記第2光学面転写面との間に前記第2フランジ面転写面が形成されており、
前記第1の型と前記第2の型との型締め時に、前記第1位置決め部と前記第2位置決め部とを嵌合させることにより、型同士の位置決めを行う工程と、
前記第1光学転写面及び前記第1フランジ面転写面と、前記第2光学転写面及び前記第2フランジ面転写面とで囲われたキャビティ内に充填されたエネルギー硬化性樹脂にエネルギーを付与して前記エネルギー硬化性樹脂を硬化させる工程とを有することを特徴とする。 In order to achieve at least one of the objects described above, a method for manufacturing an optical element reflecting one aspect of the present invention includes the following.
A manufacturing method for molding an optical element using an energy curable resin supplied between a first mold and a second mold,
At least one of the first mold and the second mold is made of resin or glass,
A first optical surface transfer surface for transferring the first optical surface of the optical element and a first flange surface formed around the first optical surface of the optical element are transferred to the first mold. A first flange surface transfer surface, and a first positioning portion, wherein the first flange surface transfer surface is formed between the first positioning portion and the first optical surface transfer surface,
The second mold includes a second optical surface transfer surface for transferring the second optical surface of the optical element, and a second flange surface transfer surface formed around the second optical surface of the optical element. And a second positioning portion, and the second flange surface transfer surface is formed between the second positioning portion and the second optical surface transfer surface,
A step of positioning the molds by fitting the first positioning part and the second positioning part during clamping of the first mold and the second mold;
Energy is applied to an energy curable resin filled in a cavity surrounded by the first optical transfer surface and the first flange surface transfer surface, and the second optical transfer surface and the second flange surface transfer surface. And a step of curing the energy curable resin.
B 第2の処理部
C 第3の処理部
D 第4の処理部
AC アクチュエータ
AS エアスライダ
AX1 軸線
AX2 軸線
CP カム板
CPa カム面
CPb 低部
CPc 斜面
CPd 高部
CPe 斜面
DC1 第1の円盤
DC1a 円形開口
DC2 第2の円盤
DC2a 円形開口
DSP ディスペンサ
FL 光学素子のフランジ部
FL1 第1フランジ面
FL2 第2フランジ面
FL3 外周面
FW フォロワ
HLD ホルダ
HPL 熱可塑性樹脂
MD1 上型
MD1a 第1型部品
MD1b 第1光学面転写面
MD1c 第1フランジ面転写面
MD1d 円筒部
MD1e テーパ面
MD1e 内周面
MD1f 突き当て面
MD1g テーパ面
MD1i 凸部
MD1j 内周面
MD2 下型
MD2a 第2型部品
MD2b 第2型部材
MD2c 第2光学面転写面
MD2d 第2フランジ面転写面
MD2e テーパ面又は外周面
MD2f 平面
MD2g テーパ面
MD2h 突起
MD2i 外側面
MD2j 平面
MM 母型
MMa 母光学面転写面
MMb 母フランジ面転写面
MMc 部転写面
OE 光学素子
OPS 光源
P 外縁
PL 光硬化性樹脂
RB ロボット
S1 光学面
S2 光学面
SFT 回転軸
SH 遮蔽部
SP 支持部
SPS スペーサ
SPSa 開口
T 切削工具 A 1st processing part B 2nd processing part C 3rd processing part D 4th processing part AC Actuator AS Air slider AX1 Axis line AX2 Axis line CP Cam plate CPa Cam surface CPb Lower part CPc Slope CPd High part Cpe Slope DC1 First disk DC1a Circular opening DC2 Second disk DC2a Circular opening DSP Dispenser FL Optical element flange portion FL1 First flange surface FL2 Second flange surface FL3 Outer surface FW Follower HLD Holder HPL Thermoplastic resin MD1 Upper mold MD1a First Mold part MD1b First optical surface transfer surface MD1c First flange surface transfer surface MD1d Cylindrical portion MD1e Tapered surface MD1e Inner peripheral surface MD1f Abutting surface MD1g Tapered surface MD1i Protruding portion MD1j Inner peripheral surface MD2 Below MD2a Second mold part MD2b Second mold member MD2c Second optical surface transfer surface MD2d Second flange surface transfer surface MD2e Tapered surface or outer peripheral surface MD2f Planar MD2g Tapered surface MD2h Protrusion MD2i Outer surface MD2j Planar MM Master mold MMa Mother optical surface transfer Surface MMb Mother flange surface transfer surface MMc Part transfer surface OE Optical element OPS Light source P Outer edge PL Photo-curing resin RB Robot S1 Optical surface S2 Optical surface SFT Rotating shaft SH Shielding part SP Support part SPS Spacer SPSa Opening T Cutting tool
Claims (8)
- 第1の型と第2の型との間に供給されたエネルギー硬化性樹脂を用いて光学素子を成形する製造方法であって、
前記第1の型と前記第2の型の少なくとも一方は、樹脂又はガラスにより形成されており、
前記第1の型には、前記光学素子の第1の光学面を転写する第1光学面転写面と、前記光学素子における前記第1の光学面の周囲に形成される第1フランジ面を転写する第1フランジ面転写面と、第1位置決め部とを有し、前記第1位置決め部と前記第1光学面転写面との間に前記第1フランジ面転写面が形成されており、
前記第2の型には、前記光学素子の第2の光学面を転写する第2光学面転写面と、前記光学素子における前記第2の光学面の周囲に形成される第2フランジ面転写面と、第2位置決め部とを有し、前記第2位置決め部と前記第2光学面転写面との間に前記第2フランジ面転写面が形成されており、
前記第1の型と前記第2の型との型締め時に、前記第1位置決め部と前記第2位置決め部とを嵌合させることにより、型同士の位置決めを行う工程と、
前記第1光学転写面及び前記第1フランジ面転写面と、前記第2光学転写面及び前記第2フランジ面転写面とで囲われたキャビティ内に充填されたエネルギー硬化性樹脂にエネルギーを付与して前記エネルギー硬化性樹脂を硬化させる工程とを有することを特徴とする光学素子の製造方法。 A manufacturing method for molding an optical element using an energy curable resin supplied between a first mold and a second mold,
At least one of the first mold and the second mold is made of resin or glass,
A first optical surface transfer surface for transferring the first optical surface of the optical element and a first flange surface formed around the first optical surface of the optical element are transferred to the first mold. A first flange surface transfer surface, and a first positioning portion, wherein the first flange surface transfer surface is formed between the first positioning portion and the first optical surface transfer surface,
The second mold includes a second optical surface transfer surface for transferring the second optical surface of the optical element, and a second flange surface transfer surface formed around the second optical surface of the optical element. And a second positioning portion, and the second flange surface transfer surface is formed between the second positioning portion and the second optical surface transfer surface,
A step of positioning the molds by fitting the first positioning part and the second positioning part during clamping of the first mold and the second mold;
Energy is applied to an energy curable resin filled in a cavity surrounded by the first optical transfer surface and the first flange surface transfer surface, and the second optical transfer surface and the second flange surface transfer surface. And a step of curing the energy curable resin. - 樹脂又はガラスにより形成されてなる少なくとも前記一方の型は、金属製の母型から成形されており、前記母型は、少なくとも光学面転写面を転写する母光学面転写面と、位置決め部を転写する母位置決め部転写面を同軸で機械加工され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。 At least one of the molds made of resin or glass is molded from a metal mother mold, and the mother mold transfers at least a mother optical surface transfer surface that transfers the optical surface transfer surface and a positioning portion. The optical element manufacturing method according to claim 1, wherein the mother positioning portion transfer surface is machined coaxially.
- 前記第1位置決め部と前記第2の位置決め部の一方は、円筒内周面形状を有し、他方は円筒外周面形状を有することを特徴とする請求項1又は2に記載の光学素子の製造方法。 3. The optical element manufacturing method according to claim 1, wherein one of the first positioning portion and the second positioning portion has a cylindrical inner peripheral surface shape, and the other has a cylindrical outer peripheral surface shape. Method.
- 前記第1位置決め部と前記第2の位置決め部の一方は、テーパ内周面形状を有し、他方はテーパ外周面形状を有することを特徴とする請求項1又は2に記載の光学素子の製造方法。 3. The optical element according to claim 1, wherein one of the first positioning portion and the second positioning portion has a tapered inner peripheral surface shape, and the other has a tapered outer peripheral surface shape. Method.
- 前記第1位置決め部と前記第2の位置決め部の一方は、円筒内周面形状を有し、他方はテーパ外周面形状を有することを特徴とする請求項1又は2に記載の光学素子の製造方法。 3. The optical element manufacturing method according to claim 1, wherein one of the first positioning portion and the second positioning portion has a cylindrical inner peripheral surface shape, and the other has a tapered outer peripheral surface shape. Method.
- 前記第1の型と前記第2の型のうち少なくとも一方を、前記一方の型の軸線に交差する方向に、前記第1の型と前記第2の型のうち他方に対して相対移動可能に保持することを特徴とする請求項1~5のいずれかに記載の光学素子の製造方法。 At least one of the first mold and the second mold can be moved relative to the other of the first mold and the second mold in a direction intersecting the axis of the one mold. 6. The method of manufacturing an optical element according to claim 1, wherein the optical element is held.
- 前記第1の型と前記第2の型のうち少なくとも一方を,エアスライダにより保持することを特徴とする請求項6に記載の光学素子の製造方法。 The method for manufacturing an optical element according to claim 6, wherein at least one of the first mold and the second mold is held by an air slider.
- 請求項1~7のいずれかに記載の製造方法であって、
第1の処理部において、前記第1の型と前記第2の型とを型締めし、
第2の処理部において、供給された前記エネルギー硬化性樹脂にエネルギーを付与して硬化させ、
第3の処理部において、前記第1の型と前記第2の型とを型開きし、
第4の処理部において、前記第1の型と前記第2の型との間から、成形された光学素子を取り出し、
前記第1の型と前記第2の型とは、閉じた軌跡に沿って、前記第1の処理部から前記第4の処理部へと相対的に移動し且つ前記第4の処理部から前記第1の処理部へと戻ることを特徴とする光学素子の製造方法。 The production method according to any one of claims 1 to 7,
In the first processing unit, the first mold and the second mold are clamped,
In the second processing unit, energy is applied to the supplied energy curable resin to be cured,
In the third processing unit, the first mold and the second mold are opened,
In the fourth processing unit, the molded optical element is taken out from between the first mold and the second mold,
The first mold and the second mold move relatively from the first processing unit to the fourth processing unit along a closed trajectory and from the fourth processing unit Returning to a 1st process part, The manufacturing method of the optical element characterized by the above-mentioned.
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CN105283290B (en) | 2017-07-21 |
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