WO2019075937A1 - 透镜的加工设备及其加工方法 - Google Patents

透镜的加工设备及其加工方法 Download PDF

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Publication number
WO2019075937A1
WO2019075937A1 PCT/CN2018/071419 CN2018071419W WO2019075937A1 WO 2019075937 A1 WO2019075937 A1 WO 2019075937A1 CN 2018071419 W CN2018071419 W CN 2018071419W WO 2019075937 A1 WO2019075937 A1 WO 2019075937A1
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WO
WIPO (PCT)
Prior art keywords
roller
structural
glue
mirror
roll
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PCT/CN2018/071419
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English (en)
French (fr)
Inventor
王杰
胡飞
王霖
李屹
Original Assignee
深圳光峰科技股份有限公司
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Publication of WO2019075937A1 publication Critical patent/WO2019075937A1/zh

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Classifications

    • 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
    • B29D11/00019—Production of simple or compound lenses with non-spherical faces, e.g. toric faces
    • 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
    • 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
    • B29D11/00442—Curing the lens material
    • 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
    • B29D11/00951—Measuring, controlling or regulating

Definitions

  • the invention relates to a processing device for a lens and a processing method thereof, and belongs to the technical field of optical component manufacturing.
  • the large-sized annular grooved lens is a lens with a smooth side and a concentric circle or Archimedes spiral on the other side. It is widely used in various industries, such as: application in the sun.
  • the field is one of the important optical components in the concentrating solar energy system (CPV). Its performance directly affects the concentration of the CPV system.
  • CPV concentrating solar energy system
  • the light of the large divergence angle is collected, so that the originally divergent light can be concentrated in the viewer's perspective to achieve the purpose of increasing the brightness of the image. In this context and market demand, it is necessary and necessary to produce a high-precision, high-quality structure.
  • the processing method of the annular groove structure in the prior art mostly uses a large machine tool to burn a mold, and then is integrally cast or molded by using the burned mold, or directly ground and burned on the lens substrate.
  • the card control measures for thickness uniformity, the deformation before curing after glue molding, and the elimination of glue/base low-surface bubbles are lacking.
  • the process is relatively simple, and the uniformity of 4V light-solid adhesive application cannot be guaranteed; the structural roller is rolled.
  • the structure obtained after curing can not guarantee the stability of the structure (4V glue fluidity); the influence of bubbles in the glue cannot be completely eliminated; it cannot be applied to large-scale continuous production.
  • the technical problem to be solved by the present invention is to provide a processing device for a lens and a processing method thereof according to the deficiencies of the prior art, and the finished product has good appearance and uniformity, and is particularly suitable for the production and application of a large-sized display screen. Improve product yield, reduce costs, and ensure that the screen has better visual effects.
  • a processing device for a lens mainly comprising a conical round roller linkage assembly, the conical roller linkage assembly comprising a discharge roller, a drive roller, a mirror roller, a structural roller and a small radius end connected to each other by a bearing a collecting roller, each of the conical round rollers in the tapered round roller linkage assembly may be circumferentially moved around its connecting end; the structural roller surface is stacked with an annular groove structure; the production equipment Including a glue injection circulation mechanism, injecting glue into a gap between the mirror roll and the structure roll; the production apparatus includes a curing mechanism disposed under the structure roll; a substrate sequentially passes through a discharge roll, a drive roll Passing through the gap between the mirror roll and the structural roll, passing through the curing mechanism and receiving the material through the take-up roll, forming a through-mold path in the processing equipment of the lens.
  • the threading path is in an "S" shape. Specifically, the substrate is output from the discharge roller, passes through the driving roller, and penetrates from the mirror roller into the gap between the mirror roller and the structural roller, from below the structural roller. It is passed over the curing mechanism and is received by the receiving roller.
  • the production apparatus includes a pitch control mechanism for controlling a running process of the substrate in a production mode; specifically, the pitch control mechanism includes a cylinder and a pressure roller disposed between the structural roller and the take-up roller In the non-production mode, the structural roll and the pressure roll are in a non-pressed release state; in the production mode, the cylinder drives the pressure roll to control the progress of the substrate operation.
  • the production apparatus further includes an adjustment mechanism; the adjustment mechanism includes a stopper disposed between the mirror roller and the structural roller; In the non-production mode, the mirror roll and the structural roll are in a non-pressed release state; in the production mode, the cylinder drives a limiter to control the size of the gap between the mirror roll and the structural roll; the limiter includes: a screw , roller screw or linear gear.
  • the glue injection circulation mechanism includes a rubber stopper disposed between the mirror roller and the structural roller, and the outer wall of the rubber stopper and the mirror roller and the structural roller is surrounded by a V-shaped groove injection molding. Space, the rubber hose and the rubber hose are respectively arranged on both sides of the rubber stopper;
  • the excess glue is returned from the rubber returning tube to the storage tank through the first filtering device under the action of the rubberizing drive pump, and the storage tank is passed through the storage tank.
  • the heated glue passes through the second filtering device, it is re-injected from the feeding tube under the action of the feeding driving pump, so that the operation is repeated;
  • the storage tank includes a glue storage tank located at a middle portion and a heating layer integrally covering a periphery of the glue storage tank, and the heating layer stores hot water therein.
  • the feed pump and the glue drive pump specifically include a rotor pump, a screw pump, a peristaltic pump, a diaphragm pump or a gear pump.
  • the glue is a photo-curable glue having a viscosity in the range of 50 to 500 centipoise, as needed.
  • the curing mechanism is composed of a plurality of light sources having the same wavelength band, and the effective irradiation area is the structural roller.
  • the number of the driving rollers is plural, and the through-mold path of the substrate between the plurality of driving rollers is "S" shaped.
  • the substrate is a curved film surface whose arc angle is corresponding to the angle of each of the conical round rollers in the conical roller linkage assembly.
  • the substrate is sufficiently long, and the substrate comprises a plurality of single-stage curved substrates bonded by high-temperature tape.
  • the present invention also provides a processing method of a processing apparatus for a lens as described above, comprising the steps of:
  • Step 100 Turn on the production equipment and run at a lower speed until the film surface of the substrate is flat;
  • Step 300 Open the rubber hose and the rubber hose, and open the curing mechanism
  • Step 400 The glue passes through the structural gap between the mirror roll and the structure roll to form a structure with the groove on the surface of the same structure, and then reaches the solidified area of the curing mechanism to complete the instant curing to obtain the finished product.
  • step 100 further includes:
  • Step 200 Start the distance control mechanism and the adjustment mechanism, press the mirror roller and the pressure roller under the driving of the driving cylinder, and adjust the gap between the mirror roller and the structural roller to be within the effective range.
  • step 200 and the step 300 further include:
  • Step 210 Install glue to inject the rubber stopper in the circulation mechanism.
  • the through-mold path of the substrate in the production equipment is in an "S" shape, and specifically includes: outputting from the discharge roller, passing through the transmission roller, penetrating into the gap between the mirror roller and the structural roller from above the mirror roller, The lower side of the structural roller and the upper side of the curing mechanism are passed out, and the material is received by the receiving roller.
  • the present invention provides a lens processing apparatus and a processing method thereof, which have the following advantages: 1. Through the gap control between the tapered mirror wheel and the structural roller, the amount of glue is accurately ensured, and the loss is reduced; 2. The structural forming method For the side forming and curing mode, the non-first molding and post-cure mode, the obtained structural angle is accurate; 3. In view of the above-mentioned molding method, the viscosity of the glue can be selected, and the glue can be stored and circulated in the V-groove between the two wheels, and the glue can be completely excluded. The inner bubble and the impurities in the glue are prevented from damaging the structural roller; 4.
  • All the guide rollers are the same as the taper and the same center of the structural roller, which solves the problem of the difference between the inner and outer diameters of the tapered guide roller; 5, the annular substrate with the same curvature is selected. It can realize the continuous production of rolls to rolls, greatly increase the production capacity and reduce the scrap.
  • FIG. 1 is a perspective view showing the overall structure of a production apparatus of the present invention
  • FIG. 2 is a schematic plan view showing the overall structure of the production equipment of the present invention.
  • FIG. 3 is a schematic view showing a partial arrangement position of a mirror roll, a structure roll and a curing mechanism according to the present invention
  • Figure 4 is a schematic view of the distance control mechanism and the adjustment mechanism of the present invention.
  • Figure 5 is a schematic structural view of a position limiter of the present invention.
  • Figure 6 is a schematic view showing the position of the limit stopper rubber jig between the mirror roller and the structural roller;
  • FIG. 7 is a schematic structural view of a limit stopper rubber jig according to the present invention.
  • Figure 8 is a schematic view of the glue injection cycle mechanism of the present invention.
  • Figure 9 is a schematic view showing the connection structure of the substrate of the present invention.
  • Figure 10 is a schematic view of the finished lens of the invention with an annular groove microstructure.
  • FIG. 1 is a schematic perspective view of the overall structure of the production equipment of the present invention
  • FIG. 2 is a plan view showing the overall structure of the production equipment of the present invention
  • FIG. 3 is a schematic view showing a partial arrangement position of the mirror roller, the structural roller and the curing mechanism of the present invention.
  • the present invention provides a processing apparatus for a lens, the production apparatus mainly comprising a conical round roller linkage assembly, wherein the conical circular roller linkage assembly includes a small radius end connected to each other through a bearing.
  • the feed roller 1, the drive roller 2, the mirror roller 3, the structural roller 5, and the take-up roller 7, each of the tapered round roller linkages can be circularly moved around its connecting end.
  • the surface of the mirror roller 3 is plated with a hard metal coating, and the surface of the structural roller 5 is superposed with an annular groove structure.
  • the production apparatus includes a glue injection circulation mechanism that injects glue into a gap between the mirror roll 3 and the structural roll 5; the production apparatus includes a curing mechanism 4 disposed under the structural roll 5; the production The apparatus includes a pitch control mechanism for controlling a running process of the substrate in a production mode; the production apparatus further includes an adjustment mechanism for adjusting a size of a gap between the mirror roller 3 and the structural roller 5; a substrate C
  • the output from the discharge roller 1 passes through the transmission roller 2, penetrates the gap between the mirror roller 3 and the structural roller 5 from above the mirror roller 3, passes through the lower portion of the structural roller 5 and above the curing mechanism 4, and passes through the receiving roller. 7 Receipt, the path of the mold in the entire production equipment is "S" shape.
  • the distance control mechanism includes a cylinder 13 and a pressure roller 6 disposed between the structural roller 5 and the take-up roller 7.
  • the structural roller 5 and the pressure roller 6 are in a non-pressed release state; in the production mode, the cylinder 13 drives the pressure roller 6 to control the progress of the substrate C.
  • the thickness of the glue is controlled, and an adjustment mechanism is further disposed between the mirror roller 3 and the structural roller 5, and the adjustment mechanism is disposed between the mirror roller 3 and the structural roller 5.
  • Limiter 14 is a schematic view of the distance control mechanism and the adjustment mechanism of the present invention.
  • the distance control mechanism includes a cylinder 13 and a pressure roller 6 disposed between the structural roller 5 and the take-up roller 7.
  • the structural roller 5 and the pressure roller 6 are in a non-pressed release state; in the production mode, the cylinder 13 drives the pressure roller 6 to control the progress of the substrate C.
  • the thickness of the glue is controlled, and an adjustment mechanism is further disposed between the mirror roller 3 and the structural roller 5, and the adjustment mechanism is disposed
  • the mirror roller 3 and the structural roller 5 are in a non-pressed release state; in the production mode, the cylinder 13 drives the stopper 14 to control the size of the gap between the mirror roller 3 and the structural roller 5; It is required that the stopper 14 may include various structures such as a screw, a roller screw or a linear gear. That is to say, the mirror roller 3 and the pressure roller 6 are both in a non-pressing state in the non-production mode and the structural roller 5, and are pressed in the production mode by the control cylinder 13, while the mirror roller 3 and the structural roller 5 are correspondingly The gap is controlled by the limiter 14 to reach the distance limit.
  • FIG. 5 is a schematic structural view of a position limiter of the present invention.
  • the stopper 14 specifically includes a screw adjusting shaft 24 and a cam adjusting mechanism 25, and the adjusting disc of the top end of the shaft 24 is adjusted by the screw.
  • the clockwise or counterclockwise rotation is performed to drive the cam mechanism 25 to rotate, thereby driving the mirror roller 3 to move closer to or away from the structural roller 5, so as to precisely adjust the spacing between the mirror roller 3 and the structural roller 5.
  • the range of the advancement can be adjusted from 50 um to 1000 um.
  • the embodiment shown in FIG. 5 is only one example of an applicable adjustment manner, and other mechanical structures may also be implemented, such as a roller screw or a linear gear, etc., and those skilled in the art may The structure needs to be selected and will not be described here.
  • FIG. 6 is a schematic view showing the position of the limit stop rubber jig between the mirror roll and the structure roll
  • FIG. 7 is a schematic view showing the structure of the limit block rubber jig according to the present invention
  • FIG. 8 is a schematic view of the glue injection cycle mechanism of the present invention.
  • the glue injection circulation mechanism includes a rubber stopper 11 disposed between the mirror roller 3 and the structural roller 5, and the shape of the stopper rubber 11 is shown in combination with FIG.
  • the first side 17 is the radius corresponding to the mirror roller 3, and the second side 18 is the radius corresponding to the structural roller 5.
  • the material requires a lower frictional surface and a better anti-friction deformation effect.
  • the outer wall of the rubber stopper 11 and the mirror roller 3 and the structural roller 5 is surrounded by a V-shaped groove-shaped injection space, and the rubber hose 8 and the rubber hose 9 are respectively disposed on both sides of the rubber stopper 11; After the injection rubber tube 8 is injected into the injection space by the rubber feed pump 22, the excess glue is returned from the rubber hose 9 to the storage tank through the first filter device 21 under the action of the rubber return drive pump 23, After the heated glue in the storage tank passes through the second filtering device 30, it is again refilled from the feeding tube 8 by the feeding driving pump 22, and the operation is repeated.
  • the storage tank includes a glue storage tank 20 located at the middle portion and a heating layer 19 integrally covering the periphery of the glue storage tank 20, wherein the heating layer stores hot water.
  • the hot water in the heating layer 19 can be realized by means of cyclic heating, which is a conventional technical means in the art, and will not be described herein.
  • the invention adopts the above-mentioned circulation mechanism, which not only completes the heating of the glue, but also achieves the circulation effect, so as to ensure the cleaning of the glue and the better reaction conditions.
  • the glue injection and circulation mechanism is provided with a flow control component, that is, a glue drive pump 22 and a glue drive pump 23, and the feed drive pump 22 and the glue drive pump 23 may specifically include: Rotor pump, screw pump, peristaltic pump, diaphragm pump or gear pump, etc.
  • the speed can be manually adjusted to achieve accurate, Effectively control the purpose of glue in/out flow.
  • the glue is a photo-curable glue having a viscosity in the range of 50 to 500 centipoise, as needed.
  • the filter element in the first filter device 21 and the second filter device 30 has an optional range of 1 um to 300 um.
  • the curing mechanism 4 is composed of a plurality of light sources having the same wavelength band, and the effective irradiation area is a structure.
  • the area under the roll 5 is wrapped.
  • the light source may be a 4V light source or an ultraviolet light tube, as needed.
  • the number of the driving rollers 2 is plural, and the through-mold path of the substrate between the plurality of driving rollers is "S" shaped.
  • the discharge roller 1, the driving roller 2, the mirror roller 3, the structural roller 5, and the take-up roller 7 are all tapered round rollers, since all the guide rollers are tapered, and the DS/OS side belongs to the substrate moving line.
  • the speed is inconsistent, so the substrate is required to be a curved film surface with the angle of the tapered roller, that is, the substrate C is a curved film surface, and the arc angle is corresponding to the angle of the tapered roller.
  • All tapered rollers are made of soft materials such as rubber or hard, such as metal mirrors.
  • Figure 9 is a schematic view showing the connection structure of the substrate of the present invention.
  • the substrate is ensured to be sufficiently long, and the substrate C can also be spliced by a single-stage curved substrate, and the curved single-stage substrate 15 is spliced by the high-temperature resistant tape 16 into The desired shape, sufficient tensile strength to avoid breakage when passing through the curing zone of the curing mechanism.
  • the present invention also provides a processing method of a processing apparatus for a lens as described above, comprising the following steps:
  • Step 100 Turn on the production equipment and run at a lower speed until the film surface of the substrate C is flat;
  • the substrate C has an "S" shape in the production equipment, and is outputted from the discharge roller 1 through the transmission roller 2, and penetrates the mirror roller 3 and the structural roller from above the mirror roller 3. In the gap of 5, it is taken out from below the structural roller 5 and above the curing mechanism 4, and is received by the take-up roller 7.
  • Step 200 Starting the distance control mechanism and the adjusting mechanism, pressing the mirror roller 3 and the pressure roller 6 under the driving of the driving cylinder 13; simultaneously adjusting the gap between the mirror roller 3 and the structural roller 5 so as to be within the effective range
  • the effective range described is the range of gaps that can be smoothly processed. In the application, the specific numerical range can be determined according to actual needs.
  • Step 300 install glue into the rubber stopper 11 in the circulation mechanism, open the rubber tube 8 and the rubber hose 9, and open the curing mechanism 4;
  • Step 400 The glue passes through the structural gap between the mirror roll 3 and the structure roll 5 to form a structure with the same groove on the surface of the structure roll 5, and then reaches the solidified area of the curing mechanism 4, and the instant curing is completed to obtain a finished product.
  • Fig. 10 is a schematic view showing the finished lens of the invention with an annular groove microstructure. As can be seen from Fig. 10, the surface of the molded product has an annular groove microstructure.
  • the present invention provides a lens processing apparatus and a processing method thereof, and the beneficial effects thereof include the following points:
  • the structural forming method is the side forming side curing mode, the non-first forming and post-cure mode, and the obtained structural angle is accurate;
  • the glue with lower viscosity can be selected, and the glue is stored and circulated in the V-shaped groove between the two wheels, and the bubbles in the glue can be completely eliminated and the structural roller can be prevented from being damaged by the impurities in the glue;
  • All the guide rollers are the same as the taper and the same center of the structural roller, which solves the problem of the difference between the inner and outer diameters of the tapered guide roller;
  • the annular substrate with the same curvature can be used to realize the continuous production of the roller to the roller, which greatly increases the production capacity and reduces the scrap.
  • the invention is particularly suitable for the production and application of a large-sized display screen, improves product yield, reduces cost, and ensures a better visual effect of the screen.

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
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Abstract

一种透镜的加工设备及其加工方法，该生产设备主要包括锥形圆辊联动组件，锥形圆辊联动组件包括小半径端通过轴承彼此相连的放料辊(1)、传动辊(2)、镜面辊(3)、结构辊(5)和收料辊(7)，锥形圆辊联动组件中的每一根锥形圆辊均可以以其连接端为中心做圆周运动；结构辊(5)表面叠设有环形沟槽结构；该生产设备还包括胶水注入循环机构，将胶水注入到镜面辊(3)和结构辊(5)之间的空隙内；该生产设备还包括固化机构(4)，其设置在所述结构辊(5)的下方。加工出来的成品外观、均匀性好，特别适应于大尺寸显示屏幕的生产及应用，提高产品良率，降低成本，保证屏幕具有较佳的视觉效果。

Description

透镜的加工设备及其加工方法 技术领域
本发明涉及一种透镜的加工设备及其加工方法，属于光学部件制造技术领域。
 背景技术
大尺寸环形沟槽结构透镜是一种一面为光面，另一面刻有同心圆或阿基米德螺线的透镜，目前在各个行业中的应用越来越广泛，比如：应用在太阳聚光领域，是聚光太阳能系统（CPV）中重要的光学部件之一，其性能优劣直接影响着 CPV系统的聚光率的高低；应用在显示领域，其主要功能在于将投影机所投出的大发散角的光线收集起来，使得原来发散的光线可以集中于观众的视角内，以达到增加图像亮度的目的。在此背景及市场的需求下，制作一种高精度、高质量的结构是必要及市场必需的。
 技术问题
现有技术中的环形沟槽结构的加工方法多采用大型机床刻录模具，再用刻录好的模具进行整体浇注或模压成型，或者直接在镜片基材上进行磨削、刻录而成。现有技术中缺少对厚度均一性的卡控措施、胶水成型后固化前的形变及胶水/基低面气泡的排除措施。另外，在现有的锥形辊生产技术中，参见专利号为ZL201410170395.X的在先专利所公开的内容可知，该工艺方式较为简单，无法保证4V光固胶涂抹均匀性；结构辊滚压后所得结构固化前不能保证结构的稳定（4V胶水流动性）；无法完全排除胶水内气泡的影响；无法适用于大批量连续生产 。
 技术解决方案
本发明所要解决的技术问题在于针对现有技术的不足，提供一种透镜的加工设备及其加工方法，加工出来的成品外观性、均匀性好，特别适应于大尺寸显示屏幕的生产及应用，提高产品良率，降低成本，保证屏幕具有较佳的视觉效果。
本发明所要解决的技术问题是通过如下技术方案实现的：
一种透镜的加工设备，所述生产设备主要包括锥形圆辊联动组件，所述锥形圆辊联动组件包括小半径端通过轴承彼此相连的放料辊、传动辊、镜面辊、结构辊和收料辊，所述锥形圆辊联动组件中的每一根锥形圆辊均可以以其连接端为中心做圆周运动；所述结构辊表面叠设有环形沟槽结构；所述生产设备包括胶水注入循环机构，将胶水注入到镜面辊和结构辊之间的空隙内；所述生产设备包括固化机构，其设置在所述结构辊的下方；一基材依次经过放料辊、传动辊、从镜面辊和结构辊的间隙中穿过，再通过固化机构并经收料辊收料，在所述透镜的加工设备中形成穿模路径。所述穿模路径呈“S”形，具体来说，所述基材从放料辊上输出，经传动辊，从镜面辊上方穿入镜面辊和结构辊的间隙中，从结构辊的下方和固化机构的上方穿出，经收料辊收料。
所述生产设备包括进距控制机构，用于在生产模式下控制基材运行进程；具体来说，所述进距控制机构包括气缸和设置在所述结构辊和收料辊之间的压力辊；在非生产模式下，结构辊和压力辊处于非压制的释放状态；在生产模式下，所述气缸驱动压力辊以控制基材运行进程。
为了调整所述镜面辊和结构辊两者之间的间隙大小，控制胶水厚度，所述生产设备还包括调节机构；所述调节机构包括设置在镜面辊和结构辊之间的限位器；在非生产模式下，镜面辊和结构辊处于非压制的释放状态；在生产模式下，所述气缸驱动限位器以控制镜面辊和结构辊之间间隙的大小；所述限位器包括：螺杆、辊珠丝杆或线性齿轮。
更具体地，所述胶水注入循环机构包括设置在镜面辊和结构辊之间的挡胶治具，所述挡胶治具与镜面辊、结构辊的外壁围设成一V形槽状注胶空间，在挡胶治具的两侧分别设有进胶管和回胶管；
胶水在进胶驱动泵的作用下经进胶管注入注胶空间后，多余的胶水从回胶管在回胶驱动泵的作用下经第一过滤装置返回到储罐内，在所述储罐中经加热的胶水经第二过滤装置后再次在进胶驱动泵的作用下从进胶管重新进行注胶，如此循环作业；
所述储罐包括位于中部的胶水储罐和整体包覆在所述胶水储罐外围的加热层，所述加热层中储存有热水。
所述进胶驱动泵和回胶驱动泵具体包括：转子泵、螺杆泵、蠕动泵、隔膜泵或齿轮泵。
根据需要，所述胶水为光固胶，其粘度范围为50-500厘泊。
为了加大辊对辊模式生产设备的固化面积和时间，保证在高速生产模式下具有良好的胶水固化成型效果，所述固化机构由多个波段相同的多个光源组成，有效照射面积为结构辊的下方包裹面积。
为了增加传送长度，所述传动辊的设置数量为多个，所述基材在多个传动辊之间的穿模路径呈“S”形。
另外，所述基材为弧形膜面，其弧形角度与所述锥形圆辊联动组件中的每一根锥形圆辊的角度对应设置。
为了适应生产设备的大规模生产，保证基材足够长，所述基材包括多个由高温胶带粘接而成的单段式弧形基材。
本发明还提供一种如上所述的透镜的加工设备的加工方法，包括如下步骤：
步骤100：开启生产设备，较低速度运行直至基材的膜面平整；
步骤300：开启进胶管和回胶管，并开启固化机构；
步骤400：胶水通过镜面辊和结构辊的结构缝隙，形成同结构辊表面沟槽一致的结构后到达固化机构的固化区域，完成瞬间固化，得到成品。
进一步地，所述步骤100和步骤300之间，还包括：
步骤200：启动进距控制机构和调节机构，在驱动气缸的驱动下，压合镜面辊和压力辊，同时调整镜面辊和结构辊之间的间隙，使其处于有效范围内。
更进一步地，所述步骤200和步骤300之间还包括：
步骤210：安装胶水注入循环机构中的挡胶治具。
所述基材在生产设备中的设置的穿模路径呈“S”形，具体包括：从放料辊上输出，经传动辊，从镜面辊上方穿入镜面辊和结构辊的间隙中，从结构辊的下方和固化机构的上方穿出，经收料辊收料。
 有益效果
综上所述，本发明提供一种透镜的加工设备及其加工方法，具有以下优点： 1、通过锥形镜面轮与结构辊的间隙控制，精确保证胶水用量，降低损耗；2、结构成型方式为边成型边固化方式，非先成型后固化模式，得到的结构角度精确；3、鉴于上述的成型方式可选用粘度较低胶水，胶水在两轮间V型槽储存及循环，可完全排除胶水内气泡及避免胶水内杂质损坏结构辊；4、所有导辊均为结构辊同锥度、同圆心，解决了锥形导辊传送内外径线速度差的问题；5、选用同弧度的环形基材，可实现辊到辊的连续性生产，大幅度提高产能，降低报废。
下面结合附图和具体实施例，对本发明的技术方案进行详细地说明。
 附图说明
图1为本发明生产设备整体结构立体示意图；
图2为本发明生产设备整体结构平面示意图；
图3为本发明镜面辊、结构辊与固化机构的局部设置位置示意图；
图4为本发明进距控制机构和调节机构示意图；
图5为本发明限位器的结构示意图；
图6为本发明限位挡胶治具在镜面辊和结构辊间的设置位置示意图；
图7为本发明限位挡胶治具结构示意图；
图8为本发明胶水注入循环机构示意图；
图9为本发明基材连接结构示意图；
图10为本发明带有环形沟槽微结构的透镜成品示意图。
 
 本发明的最佳实施方式
图1为本发明生产设备整体结构立体示意图；图2为本发明生产设备整体结构平面示意图；图3为本发明镜面辊、结构辊与固化机构的局部设置位置示意图。如图1至图3所示，本发明提供一种透镜的加工设备，所述生产设备主要包括锥形圆辊联动组件，所述锥形圆辊联动组件包括小半径端通过轴承彼此相连的放料辊1、传动辊2、镜面辊3、结构辊5和收料辊7，所述锥形圆辊联动组件中的每一根锥形圆辊均可以以其连接端为中心做圆周运动。所述镜面辊3的表面电镀有硬金属涂层，结构辊5的表面叠设有环形沟槽结构。所述生产设备包括胶水注入循环机构，将胶水注入到镜面辊3和结构辊5之间的空隙内；所述生产设备包括固化机构4，其设置在所述结构辊5的下方；所述生产设备包括进距控制机构，用于在生产模式下控制基材运行进程；所述生产设备还包括调节机构，用于调整所述镜面辊3和结构辊5之间间隙的大小；一基材C从放料辊1上输出，经传动辊2，从镜面辊3上方穿入镜面辊3和结构辊5的间隙中，从结构辊5的下方和固化机构4的上方穿出，经收料辊7收料，在整个生产设备中的穿模路径呈“S”形。
图4为本发明进距控制机构和调节机构示意图。如图4所示，具体来说，所述进距控制机构包括气缸13和设置在所述结构辊5和收料辊7之间的压力辊6。在非生产模式下，结构辊5和压力辊6处于非压制的释放状态；在生产模式下，所述气缸13驱动压力辊6以控制基材C运行进程。另外，为了调整两者之间的间隙大小，控制胶水厚度，所述镜面辊3和结构辊5之间还设有调节机构，所述调节机构包括设置在镜面辊3和结构辊5之间的限位器14。在非生产模式下，镜面辊3和结构辊5处于非压制的释放状态；在生产模式下，所述气缸13驱动限位器14以控制镜面辊3和结构辊5之间间隙的大小；根据需要，所述限位器14可以包括：螺杆、辊珠丝杆或线性齿轮等多种结构。也就是说，镜面辊3和压力辊6辊在非生产模式下与结构辊5都处于非压制状态，在生产模式下通过控制汽缸13进行进距压制，同时使镜面辊3和结构辊5相应的间隙通过限位器14达到进距限位可控。
图5为本发明限位器的结构示意图。如图5并结合图1、图2所示，在如图5所示的实施例中，限位器14具体包括螺杆调节轴24和凸轮调节机构25，通过对螺杆调节轴24顶端的调节盘进行顺时针或者逆时针的旋转，带动凸轮机构25转动，从而驱动镜面辊3运动，使其靠近或者远离结构辊5，达到精确调整镜面辊3和结构辊5之间间距的目的。根据凸轮调节机构25的具体尺寸，进距可调的范围为50um-1000um。需要说明的是，图5所示的实施例仅仅为可运用的调整方式之一举例，其他的机械结构也可以实现，比如：辊珠丝杠或线性齿轮等等，本领域技术人员可以根据实际的结构需要进行选择，在此不再赘述。
图6为本发明限位挡胶治具在镜面辊和结构辊间的设置位置示意图；图7为本发明限位挡胶治具结构示意图；图8为本发明胶水注入循环机构示意图。如图6至图8所示，所述胶水注入循环机构包括设置在镜面辊3和结构辊5之间的挡胶治具11，结合图7所示，限位挡胶治具11的形状，其中第一侧边17为镜面辊3所对应的半径，第二侧边18为结构辊5所对应半径，其材质要求表面较低的摩擦力及较好的抗摩擦变形效果。所述挡胶治具11与镜面辊3、结构辊5的外壁围设成一V形槽状注胶空间，在挡胶治具11的两侧分别设有进胶管8和回胶管9；胶水在进胶驱动泵22的作用下经进胶管8注入注胶空间后，多余的胶水从回胶管9在回胶驱动泵23的作用下经第一过滤装置21返回到储罐内，在所述储罐中经加热的胶水经第二过滤装置30后再次在进胶驱动泵22的作用下从进胶管8重新进行注胶，如此循环作业。为了便于给储罐中存储的胶水加热，所述储罐包括位于中部的胶水储罐20和整体包覆在所述胶水储罐20外围的加热层19，所述加热层中储存有热水，以确保证胶水处于一恒定温度。根据需要，所述加热层19中的热水可以通过循环加热的方式来实现，该部分内容属于本领域的常规技术手段，在此不再赘述。本发明采用上述循环机构，既完成了对胶水的加热，又达到了循环效果，以保证胶水的清洁及较好的反应条件。为了有效控制流量，所述胶水注入循环机构上设置了流量控制组件，即：进胶驱动泵22和回胶驱动泵23，所述进胶驱动泵22和回胶驱动泵23，具体可以包括：转子泵、螺杆泵、蠕动泵、隔膜泵或齿轮泵等等，同时，进胶驱动泵22和回胶驱动泵23除了可以连接电路进行频率控制之外，还可以手动调整转速，以达到准确、有效控制胶水进/回流量的目的。根据需要，所述胶水为光固胶，其粘度范围为50-500厘泊。另外，为了保证循环机构中胶水的清洁，第一过滤装置21和第二过滤装置30中滤芯的可选范围为1um-300um。
为了加大辊对辊模式生产设备的固化面积和时间，保证在高速生产模式下具有良好的胶水固化成型效果，所述固化机构4由多个波段相同的多个光源组成，有效照射面积为结构辊5的下方包裹面积。根据需要，所述光源可以为4V光源或紫外线灯管。
结合图1和图3所示，为了增加传送长度，所述传动辊2的设置数量为多个，所述基材在多个传动辊之间的穿模路径呈“S”形。
另外，所述放料辊1、传动辊2、镜面辊3、结构辊5和收料辊7均为锥形圆辊，因所有导辊均为锥形，DS/OS侧所属基材运动线速度不一致，故要求基材为同锥形辊角度的弧形膜面，即：所述基材C为弧形膜面，其弧形角度与锥形辊角度对应设置。所有锥形辊的材质为软质，比如：橡胶等，或硬质，比如：金属镜面等均可。
图9为本发明基材连接结构示意图。如图9所示，为了适应生产设备的大规模生产，保证基材足够长，所述基材C亦可由单段弧形基材进行拼接，弧形单段式基材15通过耐高温胶带16拼接成所需的形状，足够的抗拉伸强度避免经过固化机构的固化区域时发生断裂。
结合图1至图9所示，本发明还提供一种如上所述的透镜的加工设备的加工方法，包括如下步骤：
步骤100：开启生产设备，较低速度运行直至基材C膜面平整；
具体包括：所述基材C在生产设备中的设置的穿模路径呈“S”形，从放料辊1上输出，经传动辊2，从镜面辊3上方穿入镜面辊3和结构辊5的间隙中，从结构辊5的下方和固化机构4的上方穿出，经收料辊7收料。
步骤200：启动进距控制机构和调节机构，在驱动气缸13的驱动下，压合镜面辊3和压力辊6；同时调整镜面辊3和结构辊5之间的间隙，使其处于有效范围内；所述的有效范围就是能够进行顺利加工的间隙范围，在应用中，可以根据实际需求来确定其具体的数值范围。
步骤300：安装胶水注入循环机构中的挡胶治具11，开启进胶管8和回胶管9，并开启固化机构4；
步骤400：胶水通过镜面辊3和结构辊5的结构缝隙，形成同结构辊5表面沟槽一致的结构后到达固化机构4的固化区域，完成瞬间固化，得到成品。
图10为本发明带有环形沟槽微结构的透镜成品示意图，由图10可知，成型后的产品表面带有环形沟槽微结构。
 
综上所述，本发明提供一种透镜的加工设备及其加工方法，其有益效果包括如下几点：
1、通过锥形镜面轮与结构辊的间隙控制，精确保证胶水用量，降低损耗；
2、结构成型方式为边成型边固化方式，非先成型后固化模式，得到的结构角度精确；
3、鉴于上述的成型方式可选用粘度较低胶水，胶水在两轮间V型槽储存及循环，可完全排除胶水内气泡及避免胶水内杂质损坏结构辊；
4、所有导辊均为结构辊同锥度、同圆心，解决了锥形导辊传送内外径线速度差的问题；
5、选用同弧度的环形基材，可实现辊到辊的连续性生产，大幅度提高产能，降低报废。
本发明特别适应于大尺寸显示屏幕的生产及应用，提高产品良率，降低成本，保证屏幕具有较佳的视觉效果。
 

Claims (14)

1、一种透镜的加工设备，其特征在于，所述生产设备主要包括锥形圆辊联动组件，所述锥形圆辊联动组件包括小半径端通过轴承彼此相连的放料辊（1）、传动辊（2）、镜面辊（3）、结构辊（5）和收料辊（7），所述锥形圆辊联动组件中的每一根锥形圆辊均可以以其连接端为中心做圆周运动；
所述结构辊（5）表面叠设有环形沟槽结构；
所述生产设备还包括胶水注入循环机构，将胶水注入到镜面辊（3）和结构辊（5）之间的空隙内；
所述生产设备包括固化机构（4），其设置在所述结构辊（5）的下方。
 
2、如权利要求1所述的透镜的加工设备，其特征在于，所述生产设备包括进距控制机构，用于在生产模式下控制基材运行进程；
所述进距控制机构包括气缸（13）和设置在所述结构辊（5）和收料辊（7）之间的压力辊（6）；
在非生产模式下，结构辊（5）和压力辊（6）处于非压制的释放状态；在生产模式下，所述气缸（13）驱动压力辊（6）以控制一基材在所述透镜的加工设备上的运行进程。
 
3、如权利要求1所述的透镜的加工设备，其特征在于，所述生产设备还包括调节机构，用于调整所述镜面辊（3）和结构辊（5）之间间隙的大小；
所述调节机构包括设置在镜面辊（3）和结构辊（5）之间的限位器（14）；
在非生产模式下，镜面辊（3）和结构辊（5）处于非压制的释放状态；在生产模式下，所述气缸（13）驱动限位器（14）以控制镜面辊（3）和结构辊（5）之间间隙的大小；
所述限位器（14）包括：螺杆、辊珠丝杆或线性齿轮。
 
4、如权利要求1所述的透镜的加工设备，其特征在于，所述胶水注入循环机构包括设置在镜面辊（3）和结构辊（5）之间的挡胶治具（11），所述挡胶治具（11）与镜面辊（3）、结构辊（5）的外壁围设成一V形槽状注胶空间，在挡胶治具（11）的两侧分别设有进胶管（8）和回胶管（9）；
胶水在进胶驱动泵（22）的作用下经进胶管（8）注入注胶空间后，多余的胶水从回胶管（9）在回胶驱动泵（23）的作用下经第一过滤装置（21）返回到储罐内，在所述储罐中经加热的胶水经第二过滤装置（30）后再次在进胶驱动泵（22）的作用下从进胶管（8）重新进行注胶，如此循环作业；
所述储罐包括位于中部的胶水储罐（20）和整体包覆在所述胶水储罐（20）外围的加热层（19），所述加热层中储存有热水。
 
5、如权利要求4所述的透镜的加工设备，其特征在于，所述进胶驱动泵（22）和回胶驱动泵（23）具体包括：转子泵、螺杆泵、蠕动泵、隔膜泵或齿轮泵。
 
6、如权利要求5所述的透镜的加工设备，其特征在于，所述胶水注入循环机构中的胶水为光固胶，其粘度范围为50-500厘泊。
 
7、如权利要求1所述的透镜的加工设备，其特征在于，所述固化机构（4）由多个波段相同的多个光源组成，有效照射面积为结构辊（5）的下方包裹面积。
 
8、如权利要求1所述的透镜的加工设备，其特征在于，所述传动辊（2）的设置数量为多个，一基材在多个传动辊（2）之间的穿模路径呈“S”形。
 
9、如权利要求8所述的透镜的加工设备，其特征在于，所述基材为弧形膜面，其弧形角度与所述锥形圆辊联动组件中的每一根锥形圆辊的角度对应设置。
 
10、如权利要求9所述的透镜的加工设备，其特征在于，所述基材包括多个由高温胶带粘接而成的单段式弧形基材。
 
11、一种如权利要求1-10任一项所述的透镜的加工设备的加工方法，其特征在于，所述方法包括如下步骤：
步骤100：开启生产设备，较低速度运行直至基材的膜面平整；
步骤300：开启进胶管（8）和回胶管（9），并开启固化机构（4）；
步骤400：胶水通过镜面辊（3）和结构辊（5）的结构缝隙，形成同结构辊表面沟槽一致的结构后到达固化机构的固化区域，完成瞬间固化，得到成品。
 
12、如权利要求11所述的透镜的加工设备的加工方法，其特征在于，所述步骤100和步骤300之间，还包括：
步骤200：启动进距控制机构和调节机构，在驱动气缸（13）的驱动下，压合镜面辊（3）和压力辊（6），同时调整镜面辊（3）和结构辊（5）之间的间隙，使其处于有效范围内。
 
13、如权利要求12所述的透镜的加工设备的加工方法，其特征在于，所述步骤200和步骤300之间还包括
步骤210：安装胶水注入循环机构中的挡胶治具（11）。
 
14、如权利要求11-13任一项所述的透镜的加工设备的加工方法，其特征在于，所述基材在生产设备中的设置的穿模路径呈“S”形，具体包括：从放料辊（1）上输出，经传动辊（2），从镜面辊（3）上方穿入镜面辊（3）和结构辊（5）的间隙中，从结构辊（5）的下方和固化机构（4）的上方穿出，经收料辊（7）收料。
 
 
PCT/CN2018/071419 2017-10-16 2018-01-04 透镜的加工设备及其加工方法 WO2019075937A1 (zh)

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