JP2002096340A - Method for manufacturing optical element - Google Patents

Abstract

PROBLEM TO BE SOLVED: To dispense with rotation of both of a mold and an optical element base material in a resin spreading process and to accurately form a desired resin layer even if the optical element base material, that is, an optical element has a rotary axis asymmetric shape. SOLUTION: An energy curable resin is supplied to the optical surface of a mold or the molding surface of an optical element base material, and the mold and the optical element base material are allowed to approach relatively to spread the resin under pressure to form the desired resin layer between the mold and the optical element base material. In this case, the relative approach operation of the mold and the optical element base material after the contact of the optical surface of the mold and the resin is performed by intermittent operation repeating approach and stop at a first speed or by two kinds of speed operations repeating the approach at the first speed and the approach at a second speed slower than the first speed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing an optical element formed by laminating a resin layer on a glass substrate.

[0002]

2. Description of the Related Art Conventionally, a method for manufacturing the optical element is described in Japanese Patent Application Laid-Open No. 3-197106. This conventional method for manufacturing an optical element includes a step of forming a desired resin layer between the mold and the substrate by spreading the resin by relatively bringing the mold and the substrate closer to each other. Alternatively, the resin layer is formed with good roundness to the outer shape of the base material by relatively moving the mold and the base material while rotating at least one of the base materials around the optical axis.

[0003]

In such a conventional method for manufacturing an optical element, the center of rotation of the surface pressing the resin layer of the mold (hereinafter referred to as the mold optical surface), the center of the mold optical surface, Alternatively, if the center of rotation of the substrate supplying surface (hereinafter referred to as a molding surface) and the center of the substrate molding surface strictly coincide with each other, a resin layer having good roundness with respect to the outer shape of the substrate is formed. It is formed.

However, when the center of rotation of the optical surface of the mold is deviated from the center of the optical surface of the mold, if the mold is rotated, the center of the optical surface of the mold becomes centered on the rotation center of the optical surface of the mold. Rotate. Accordingly, the outer peripheral portion of the mold also rotates with a displacement by the same amount as the displacement between the center of rotation of the mold optical surface and the center of the mold optical surface, and as a result, the roundness of the resin layer is poor. Will occur. This phenomenon is the same even when the center of rotation of the substrate molding surface is deviated from the center of the substrate molding surface.

In Japanese Patent Application Laid-Open No. 3-197106, only a method of manufacturing an optical element having a rotationally symmetrical shape is described.
In the method described in JP-A-197106, problems such as the resin protruding from the base material or not being partially filled occur.

[0006] The present invention has been made in view of such conventional problems, and in the step of spreading the resin,
It is not necessary to rotate both the mold and the optical element substrate, and even if the optical element substrate, that is, the optical element has a non-rotational axis symmetric shape, it is possible to accurately form a desired resin layer. An object of the present invention is to provide a method for manufacturing an optical element.

[0007]

According to a first aspect of the present invention, there is provided a method of manufacturing an optical element, comprising the steps of: forming an energy-curable resin on an optical surface of a mold or a molding surface of an optical element substrate; To form a desired resin layer between the mold and the optical element substrate by spreading the resin by relatively approaching the mold and the optical element substrate, and applying energy to the resin layer. After irradiating and curing the resin layer, in the method of manufacturing an optical element for separating the cured resin layer and the mold, the mold and the optical element substrate after contacting the mold optical surface and resin The relative approach operation is an intermittent operation in which approach and stop at a first speed are repeated, or an approach at the first speed and an approach at a second speed lower than the first speed are repeated. It is characterized by including two speed operations.

The present invention will be described with reference to the conceptual diagrams of FIGS. FIG. 1 (b) shows a columnar optical element substrate 1 and its optical surface (this optical surface is a molding surface of a resin, and is hereinafter referred to as a “molding surface”). Hereinafter, referred to as “resin”) 5, a mold optical surface 2 a that is disposed above the optical base material 1 and expands and molds the resin 5.
Represents a cylindrical mold 2 having at its tip. In the figure, the resin 5 is supplied on the molding surface 1a, but the mold 2 and the optical element substrate 1 are turned upside down so that the mold optical surface 2a
The resin 5 may be supplied thereon.

FIG. 1A is a plan view of FIG. 1B and shows a circular optical element substrate 1 and a cylindrical mold 2 having a smaller diameter than the optical element substrate 1. 1 (c), (d),
(E), (f), (g), and (h) correspond to A- in FIG.
FIG. 3 is a half sectional view of a section A, schematically showing a state in which an optical element substrate 1 and a mold 2 are relatively approached to each other, and a resin layer 3 is formed by spreading a resin 5 on a mold optical surface 2a. The center (optical axis) of the optical surface 1a of the optical element substrate 1 and the mold optical surface 2
It is assumed that the centers of a coincide.

FIG. 2 schematically shows the approaching operation of the optical element substrate and the mold. The vertical axis indicates speed, and the horizontal axis indicates time. FIG. 2A shows an intermittent operation for relatively bringing the mold 2 and the optical element substrate 1 closer to each other. Mold 2 and optical element substrate 1 are A0
When the resin 5 comes into contact with the mold optical surface 2a and is spread on the molding surface 1a, the approach operation is stopped for a predetermined time B1 at that stage, and then the first speed An approach that repeats approach and stop, such as approaching again at A1, stopping at the time of B2, approaching again at the first speed A2, stopping at the time of B3 again, approaching again at the first speed A3, and so on. This operation is called an intermittent operation.

FIG. 2B shows two kinds of speed operations of approaching the mold 2 and the optical element substrate 1. The mold 2 and the optical element substrate 1 relatively approach each other at the speed of A0, and the resin 5 moves to the mold optical surface 2a.
, And thereby the molding surface 1 of the optical element substrate 1
When it is spread over a, at that stage, it switches to approaching at a slow speed that is slower than any of the first speeds for a predetermined time C1 and almost close to a stop, and then approaches again at the first speed A1. Then, approach the time C2 at the second speed close to the stop as described above, approach again at the first speed A2, and approach the time C3 at the second speed close to the stop as described above. There are at least two types of operations that repeat the approach at the first speed and the approach at the second speed that is slower than any of the first speeds, such as approaching again at the first speed A3. Therefore, it is called two-speed operation. In the following, the times C1, C2, and C3 are described, and the second speeds at the times C1, C2, and C3 are also described as C1, C2, and C3 for convenience.

The state in which the resin layer is formed by the intermittent operation or the two-speed operation by the optical element substrate 1 and the mold 2 will be described with reference to FIGS. 1 (c) to 1 (h).

FIG. 1C shows a space where the optical element substrate 1 and the mold 2 approach at a speed of A0, and the resin 5 is formed by the mold optical surface 2a and the molding surface 1a of the optical element substrate 1. Shows the state where it was pushed out. At this time, the outermost peripheral portion of the resin 5 that is not in contact with the mold optical surface 2a of the mold 2 and the molding surface 1a of the optical element substrate 1 bulges outward due to surface tension.

The outermost portion of the resin 5 means that when the resin 5 is expanded, the resin 5 spreads out in an indefinite state.
Among the spread portions of the resin 5, the portion closest to the contour of the outer peripheral portion of the mold 2 is referred to. According to this definition, the outermost peripheral portion of the resin 5 is one point, but not only that one point,
A portion having a certain area including and including the one point is referred to as “outermost portion”.

Further, the entire outer peripheral portion of the resin 5 swells outward, and FIG. 1C shows the swelling of the outermost peripheral portion. 1C, the molding surface 1a of the optical element substrate 1 and the mold optical surface 2a of the mold 2 are circular.
The molding surface 1a of the optical element substrate 1 is circular, and the mold 2 has a non-rotational axis symmetric shape other than a circle, or both the mold 2 and the optical element substrate 1 have a non-rotational axis symmetric shape other than a circle. Also in this case, the outermost peripheral portion of the resin 5 refers to a portion of the expanded resin 5 closest to the contour of the outer peripheral portion of the mold 2.

Further, in the case of FIG. 1 (c), the optical element substrate 1 and the mold 2 are used to extend a part of the irregularly shaped resin 5 which has been spread out before the intermittent operation or the two-speed operation is started. Although it was defined as a part, even when it entered intermittent operation or dual speed operation,
Each time the resin 5 is spread, its “outermost portion” exists.

Next, in this state, when the approach between the optical element substrate 1 and the mold 2 is stopped for the time B1, the outermost peripheral portion of the resin 5 which has swelled outward as shown in FIG. Draws an arc by the surface tension and enters inside. Here, the optical element substrate 1 and the mold 2 are stopped. However, if the force of the resin 5 entering inside due to surface tension is greater than the force of the resin 5 spreading outward due to the approach, the optical element substrate 1
And the mold 2 do not necessarily have to stop, but their approach speed is an approach speed close to stop, a second speed C1, for example,
If it is 0.03 mm / sec or less, the bulge of the outermost peripheral portion of the resin 5 enters inside when the surface tension is superior, as in the case of the stop. That is, as shown in FIG. 2B, the time of C1 is the same as the time of B1, and the outermost peripheral portion of the resin 5 enters inside.

When the approach between the optical element substrate 1 and the mold 2 is started again at the first speed A1 from this state, the resin 5 is spread again, and the molding of the optical surface 2a of the mold and the optical element substrate 1 is performed. The portion of the space formed by the surface 1a that is not yet filled with the resin 5 is filled. As a result of the resin 5 being spread as described above, a part thereof becomes the outermost peripheral portion, and FIG.
As shown in (e), it reaches the outer periphery of the mold 2 and swells outward due to surface tension. The outermost peripheral portion of the resin 5 reaching the outer peripheral portion of the mold 2 does not spread any more, and the other portion of the resin 5 is formed by the mold optical surface 2a and the molding surface 1a of the optical element substrate 1 as described above. The space which is not yet filled with the resin 5 in the space to be filled is filled.

The entire outermost portion of the resin 5 is
At or before reaching the outer circumference of B2
When the second stop for stopping the approach between the optical element substrate 1 and the mold 2 for the time shown in FIG. 1A, as shown in FIG. As described above, an arc is drawn inside by the surface tension. FIG. 2 (b)
As shown in (2), even if the approach between the optical element substrate 1 and the mold 2 is switched to the second speed C2 for the time C2, the resin 5 enters inside as described above.

Subsequently, when the optical element substrate 1 and the mold 2 are approached again at the first speed A2, when the entire outermost portion of the resin 5 has not reached the outer periphery of the mold 2, Stop B2
Alternatively, all the outer peripheral portions of the resin 5 that have not reached the outer peripheral portion of the mold 2 at the stage of the second speed C2 reach the outer peripheral portion of the mold 2.

At this stage, if the relative approach operation between the optical element substrate 1 and the mold 2 is completed, the resin layer 3 having the same area as the mold optical surface 2a of the mold 2 can be formed. That is, at this stage, the molding of the resin layer 3 is completed.

In this case, as will be described later, it is necessary to reduce the supply amount of the resin 5 as compared with the case where the resin 5 is protruded from the outer peripheral portion of the mold 2 to form the resin layer 3.

This is because when the characteristics of the optical element are to be adjusted to a predetermined standard value, the thickness of the resin layer 3 at the center of the resin layer 3, that is, at the optical axis, has its own limit.
This is for preventing the resin layer 3 from being thickened by reducing the supply amount of the resin 5 by an amount protruding from the outer peripheral portion of the mold 2.

Generally, the resin layer 3 is formed by uniformly projecting the resin 5 from the outer periphery of the mold 2. Therefore, the relative approach operation between the optical element substrate 1 and the mold 2 is further continued.

When the approach is further continued, as shown in FIG. 1 (g), the resin 5 uniformly protrudes from the outer periphery of the mold 2 by a distance α to form the resin layer 3. In this case, FIG.
As shown in (e), since there is no portion that is not filled with the resin 5, the force for spreading the resin 5 becomes uniform around the outer periphery of the mold 2, and the resin 5 becomes the resin layer 3. , Resin layer 3
Is substantially uniform in all directions, and therefore, if the mold 2 is a perfect circle, the resin layer 3 also becomes a substantially perfect circle. Further, since the center of the molding surface 1a of the optical element substrate 1 and the center of the mold 2 coincide with each other, the accuracy of the roundness of the resin layer 3 formed on the optical element substrate 1 can be improved. . Thus, the molding of the resin layer 3 by the relative approach operation between the mold 2 and the optical element substrate 1 is completed.

In general, it is relatively easy to match the centers of the optical element substrate 1 and the optical surface 2a of the mold 2, but the center of the optical surface 2a of the optical element substrate 1 or the mold 2 is relatively easy. It is very difficult to make the respective rotation centers that are the driving centers coincide with each other. Therefore, according to the present invention, there is no need to rotate the optical element substrate 1 or the mold 2, and an optical element having good roundness can be easily obtained.

If the distance α cannot be equalized in all directions in the approaching operation at the first speed A2, after approaching at the third stop time B3 or at the second speed C3, By bringing the optical element substrate 1 and the mold 2 closer again at a first speed A3 for a short time, the distance α can be made substantially equal in all directions.

In the above description, for simplicity, the molding surface 1a of the optical element substrate 1 and the mold optical surface 2a of the mold 2 are both circular and flat. Even if the molding surface 1a is a spherical surface and the mold optical surface 2a of the mold 2 is a curved surface such as an aspheric surface, an optical element with good roundness can be obtained by exactly the same operation.

The present invention can also be applied to a case where the mold optical surface 2a or both the mold optical surface 2a and the molding surface 1a of the optical element substrate 1 have a shape other than a circle, that is, a non-rotationally symmetric shape.

As described above, the mold optical surface 2a of the mold 2 is brought into contact with the resin 5, and the resin 5 is brought into contact with the molding surface 1a of the optical element substrate 1.
After spreading the above, the approach between the mold 2 and the optical element substrate 1 is stopped for a predetermined time, or the approach is performed at a second speed close to the stop, and then the mold 2 is approached at the first speed. And optical element substrate 1
Is closer to the outer peripheral portion of the mold 2, that is, the outermost peripheral portion of the resin 5 in the portion of the resin that is stopped or pushed out before the second speed, does not spread any more, In the space formed by the mold optical surface 2a and the molding surface 1a of the optical element substrate 1, a portion not yet filled with the resin 5 is filled. This is because, due to the surface tension of the resin 5, a force for pushing and spreading the resin 5 is applied to the resin 5, the outermost peripheral surface of the resin 5 swells outward, and a stop or a second speed close to the stop where the force is not applied. In the state of the above, the resin 5 similarly enters the inside due to surface tension, and after approaching the inside again, when approaching again at the first speed, the resin 5 has a weak force opposing the force for spreading. This is because it spreads to unfilled portions.

Even when the shape of the mold optical surface 2a of the mold 2 is non-rotationally symmetric, the portion of the resin 5 that has reached the outer peripheral surface of the mold 2 does not spread any more, and the mold optical surface 2a The space formed by the molding surface 1a of the optical element substrate 1 is filled in a portion not yet filled with the resin, and after the space is completely filled, in the same manner as in the case where the mold optical surface 2a is circular. By the approach operation at the first speed, the resin layer 3 protrudes from the outer periphery of the mold 2 by an equal distance in all directions.

In the case where both the optical element substrate 1 and the mold 2 are non-rotationally symmetric, the features of the present invention appear particularly conspicuously. Are schematically shown. FIG. 3 is a plan view of the optical element substrate and the mold as viewed from above the mold.

In FIG. 3A, a rectangle ABCD indicates an outer shape of the optical element substrate 11, and a rectangle EFGH indicates an outer shape of the mold 12. Although not shown, the molding surface of the optical element substrate 11 and the mold optical surface of the mold 12 may be flat or have a predetermined curved surface. 3B to 3F show how the resin 15 spreads when the mold 12 is removed. The contour of the outer peripheral portion of the mold 12 is indicated by a dotted line.

As shown in FIG. 3B, the optical element substrate 1
Due to the relative approach between the mold 1 and the mold 12, the resin 15
It is expanded from the state of (a) and a part thereof reaches the long side EH of the outer periphery of the mold 12, but does not spread outside the long side EH. Subsequently, due to one or more intermittent operations or two speed operations of the mold 12 and the optical element substrate 11, the outer periphery of the resin 15 has a long side EH as shown in FIG. And the long side FG, but does not spread outside the long side EH and the long side FG, and is formed by the molding surface and the mold optical surface (not shown) of the substrate 11 and the mold 12, respectively. Spread toward the space near the short sides EF and HG where no is filled.

When the similar approaching operation continues, FIG.
As shown in FIG. 5, the outer peripheral portion of the resin 15 reaches the short sides EF and HG in addition to the long sides EH and FG.
Does not protrude outside of H, FG, EF and HG. that is,
Resin 15 is placed around the four corners E, F, G, and H on the outer periphery of the mold.
Is left behind.

FIG. 3E shows a state where the space formed by the optical element substrate 11 and the mold 12 is completely filled with the resin 15 in this manner. From the state of FIG.
When the optical element substrate 11 and the mold 12 approach each other at the first speed, the resin 15 that has reached the outer peripheral portion of the mold 12 exerts an equal force in a direction perpendicular to the side from the contour of each side. Then, the resin layer 13 protruding by an equal distance β is formed.

The reason why the resin layer 13 is expanded as described above is as follows.
In the intermittent approach operation or the two-speed approach operation between the optical element substrate 11 and the mold 12, the inside of the space formed by the molding surface of the optical element substrate 11 and the mold optical surface of the mold 12 due to surface tension. The unfilled portion of the resin 15 in the space where the force does not work is filled with the resin 15 without protruding from the outer periphery of the mold 12, and the entire space is filled with the resin 15.
When the resin 15 is filled, the resin 15 is extruded with an equal force to the outside of the contour of the outer peripheral portion of the mold 12 by a further approaching operation and spreads. The formation of the resin layer 13 is the same when the optical element substrate 11 and the mold 12 have other non-rotationally symmetric shapes.

Thus, according to the present invention, the mold optical surface 2a of the mold 2 or the mold optical surface 2a of the mold 2 and the optical element substrate 1
When both of the molding surfaces 1a are non-rotationally symmetric, an optical element having a desired resin layer can be obtained.

In the description of the present invention, three types of first speeds A1, A2, and A3 have been described for convenience of description, but the first speed in the present invention is limited to three types. Instead, one approach distance may be reduced to four or more types such as A4 and A5. Also, the approach operation at the first speed A1 has been described as being one time, but the present invention is not limited to one time. Therefore, the stop is not limited to three times of B1, B2, and B3, and the second speed is not limited to three times of C1, C2, and C3. Further, the stop B1, the second speed C1, and the like are not limited to one time, and may be plural times.

In general, it is desirable that the operations such as A1, B1, and C1 be performed a plurality of times in small increments. The reason is as follows.

As described above, the time of the approach operation including the first speed is caused by the surface tension of the resin due to the surface tension of the resin.
During the stop time or the approach operation time at the second speed, the resin 5 enters the inside of the mold optical surface 2a by the surface tension. That is, the surface tension acts in the direction inside the optical optical surface 2a. Therefore, when the approach operation at the first speed starts again, the resin is pushed out again, and the resin 5 is still filled in the space formed by the mold optical surface 2a and the molding surface 1a of the optical element substrate 1. The parts that are not filled are filled. In other words, the resin 5 spreads by the action of surface tension so as to be at the same distance from the contour of the outer periphery of the mold. If the resin 5 spreads in this manner, the resin 5 spreads uniformly on the molding surface 1a, and a desired optical element can be obtained.
If only the rotation is performed, the action of the surface tension does not sufficiently act on the force for spreading the resin 5, and the resin 5 may spread unevenly, or a part of the resin 5 may extend outside the predetermined surface.

Therefore, in order to perform the intermittent operation or the two-speed operation as many times as possible, it is desirable that the operations such as A1, B1, and C1 be performed a plurality of times in small increments.

A method of manufacturing an optical element according to claim 2 of the present invention is the method of manufacturing an optical element of claim 1, wherein the first speed is at least two or more within a range higher than the second speed. Including a plurality of speeds, performing an intermittent operation consisting of each speed and a stop or a dual speed operation consisting of each speed and a second speed a plurality of times for at least one of the first speeds It is characterized by.

In the description of the first embodiment, FIG.
Based on (a) and (b), the first speed is at least A
It has been explained that there are a plurality of speeds A1 and A2 and a speed A3 if necessary. Further, the first speeds A1, A2,
It has been described that there is the stop time B1, B2, B3 or the second speed C1, C2, C3 corresponding to A3.

Therefore, in the most extreme case, the first speed A1, A2 and the stop time B1, B2 or the second speed C
1, there is a possibility that a desired optical element can be obtained only by two intermittent operations of C2 or only two speed operations.
This is the case where the spreading of the resin is ideally performed and is limited to extremely exceptional cases.

According to the experiment of the inventor, one approach distance is reduced, for example, a combination of the first speed A1 and the first stop B1 or the approach operation at the first speed A1 and the second speed C1. It has been found that, when the combination of is performed a plurality of times, the whole resin is spread in intermittent operation or two-speed operation in small increments and the distance to the contour of the outer peripheral surface of the mold is made uniform. The reason for this is described in the first aspect of the present invention, and a duplicate description will be omitted.

Similarly, with respect to the combination of the first speed A2 and the stop time B2 or the combination of the first speed A2 and the second speed C2, it is also found that the above operation is promoted by performing these operations a plurality of times. did. As described above, if the small intermittent operation or the two-speed operation is performed, a part of the outer peripheral portion of the resin is moved before the other outer peripheral portion of the resin reaches the outer peripheral portion of the mold. The problem that when the resin layer protrudes from the part or the resin layer protrudes from the outer periphery of the mold, the entire outer periphery of the protruding resin layer becomes non-uniform with respect to the distance from the outer periphery of the mold is a problem in normal production. Almost gone in conditions. Therefore, according to the present invention, a desired optical element can be produced under normal production conditions.

The method for manufacturing an optical element according to claim 3 of the present invention is the method for manufacturing an optical element according to claim 1 or 2,
The intermittent operation is characterized by repeating the approach and the stop at the first speed at least three times each other.

Strictly speaking, when the outer peripheral portion of the resin reaches the outer peripheral portion of the mold, the outline of the outer peripheral portion of the resin does not completely coincide with the outline of the outer peripheral portion of the mold. Microscopically, part of the resin protrudes from the outer periphery of the mold, and the other part does not reach the outer periphery of the mold. As a result, the distance of the protruding resin layer from the outer periphery of the mold is not completely equal in all directions. However, if it is within the range of the allowable condition, the desired characteristics of the optical element will be satisfied. For example, the accuracy of the roundness is equal to or higher than a standard value.

Then, the inventor examined the conditions of the intermittent operation in detail, and as a result, as the number of repetitions of approach and stop at the first speed increases, the amount of protrusion from the outer periphery of the mold increases. It can be more precisely equalized in all directions, but it has been found that the effect of the present invention is recognized and the characteristics of the optical element satisfy the standard value if the number of repetitions of approach and stop is at least three or more. This is because if the resin enters the inside three times or more due to the surface tension of the resin at the time of stopping, the spread of the resin becomes uniform in all directions.

The method for manufacturing an optical element according to claim 4 of the present invention is the method for manufacturing an optical element according to claim 1 or 2,
The two-speed operation is characterized in that the approach at the first speed and the approach at the second speed are repeated at least three times each other.

According to the present invention, since the approach at the second speed is almost a stop operation, the operation is substantially the same as the operation described in the third aspect.

The method for manufacturing an optical element according to claim 5 of the present invention is the method for manufacturing an optical element according to claim 1 or 2,
The relative approach distance between the mold and the optical element base material at the first speed gradually decreases as the distance between the mold and the optical element base material decreases.

As described in the first aspect of the present invention,
When the approach between the mold and the optical element base material is stopped for a predetermined time, or the approach is made at a second speed close to the stop, and then the mold and the optical element base material are approached at the first speed. In the portion of the resin that is stopped or spread before the second speed, the portion closest to the outer periphery of the mold, that is, the outermost portion of the resin does not spread any more, the mold optical surface and the optical element substrate In the space formed by the molding surface of the above, the portion not yet filled with the resin is filled. Further, the distance that the resin protrudes from the outer peripheral portion of the optical surface of the mold is substantially equal in all directions.

Such an action occurs when the resin is pushed out by the approaching operation of the mold optical surface and the molding surface of the optical element base material, and when the approaching operation is stopped or almost equal to the stop. This is because the surface tension of the resin works when the speed is switched.

However, as the distance between the mold and the optical element substrate becomes smaller, the resin becomes thinner, and the surface tension of the resin becomes weaker. Therefore, it is necessary to control the spread of the resin so that the distance to the contour of the outer peripheral portion of the mold becomes uniform by gradually reducing the approach distance at one time because the surface tension is weakened. This is because if the approach distance is small, the influence of surface tension can be relatively increased.

The method for manufacturing an optical element according to claim 6 of the present invention is the method for manufacturing an optical element according to claim 1 or 2,
The relative approach speed of the mold and the optical element base material at the first speed gradually decreases as the distance between the mold and the optical element base material decreases.

The operation of the present invention is almost the same as the operation described in claim 5, and as shown in FIG. 2, by decreasing the approach speed of the first speed from A1 to A3,
The influence of the surface tension of the resin is relatively increased to compensate for the decrease in the surface tension due to the thinning of the resin layer, and the control of the spread of the resin is maintained.

The method for manufacturing an optical element according to claim 7 of the present invention is the method for manufacturing an optical element according to claim 1 or 2,
The time to stop the relative approach of the mold and the optical element substrate, as the distance between the mold and the optical element substrate decreases,
It is characterized in that it becomes longer stepwise.

The operation of the present invention is almost the same as the operation described in claim 5 or 6, and as shown in FIG. 2, by increasing the stop time from B1 to B3,
The influence of the surface tension of the resin is relatively increased to compensate for the decrease in the surface tension, and control of the spread of the resin is maintained. In the stop time, the action of the surface tension of the resin trying to enter the inside of the optical surface of the mold plays an important role in controlling the spread of the resin as described above, and in particular,
At the stage where the distance between the mold and the optical element base material is reduced, by increasing the stop time, there is a function of preventing the resin from irregularly protruding from the outer peripheral portion of the optical surface of the mold, and as a result, The resin spreads uniformly from the outer periphery of the mold.

The method for manufacturing an optical element according to claim 8 of the present invention is the method for manufacturing an optical element according to claim 1 or 2,
The approach operation time at the second speed gradually increases as the distance between the mold and the optical element base material decreases.

According to the operation of the present invention, the approach operation at the second speed is slow, so that the effect of the surface tension of the resin is almost the same as the case where the mold and the optical element substrate are stopped. Accordingly, the operation is substantially the same as the operation of the stop time according to the seventh aspect, controls the spread of the resin, and prevents the resin from irregularly protruding from the outer peripheral portion of the optical surface of the mold.

According to a ninth aspect of the present invention, in the method of manufacturing an optical element, an energy-curable resin is supplied to an optical surface of a mold or a molding surface of an optical element base material, and the mold and the optical element base material are moved relative to each other. Forming a desired resin layer between the mold and the optical element substrate by spreading the resin by close proximity to each other, irradiating the resin layer with energy to cure the resin layer, and then setting the cured resin In the method of manufacturing an optical element for separating a layer and a mold, an outer peripheral shape of the optical surface of the mold is a rotational axis symmetrical shape, and the mold and the optical element base after contacting the optical surface of the mold with a resin. The relative approach operation of the material is a continuous approach operation, followed by an intermittent operation in which the stop and the approach at the first speed are repeated, or an approach at the second speed lower than the first speed and the second approach. It is a two-speed operation that repeats approaching at one speed And it features.

In the present invention, since the shape of the optical element base material which forms the optical element by forming the resin layer is symmetric with respect to the rotational axis like a circular lens, the shape of the mold optical surface is changed to the optical element base material. To the shape of the rotation axis. Further, in the present invention, the relative approach operation between the optical element base material and the mold, and the stage before the optical surface of the mold spreads the resin, as a matter of course, continues to a part of the step of spreading the resin. In this way, the mold and the optical element base material are brought closer to each other to shorten the tact time for manufacturing the optical element, thereby reducing the cost of the optical element. It is desirable that the speed of the continuous approach operation is higher than the first speed in the intermittent approach operation or the two-speed operation performed thereafter.
The intermittent operation or the two-speed operation performed after the continuous approach operation is the same as that described in the first aspect of the present invention, and thus the description thereof is omitted.

The method for manufacturing an optical element according to claim 10 of the present invention is the method for manufacturing an optical element according to claim 9, wherein the continuous approaching operation has the same center and the same diameter as the optical surface of the mold. It is characterized in that it is an approach operation of the mold and the optical element base material until at least part of the resin protrudes from the inside of the 80% circle of the mold optical surface.

In the present invention, a part of the resin means an outermost peripheral portion of the resin. The spread of the resin in the continuous approaching operation is indefinite, and as described above, since control using the surface tension of the resin is not performed, if the continuous approaching operation is performed too long from the time when the resin starts to be spread out, There is a problem that the outermost peripheral portion of the resin protrudes beyond the outer peripheral portion of the optical element substrate.

Therefore, when the outermost peripheral portion of the resin reaches the circumference of 80% of the diameter of the optical surface of the mold, which is symmetrical with the rotation axis and circular, the optical element base material and the mold are separated. The invention according to claim 1, wherein the approaching operation is stopped, and then the intermittent operation is performed, or the approaching operation between the optical element substrate and the mold is switched to the second-speed approaching operation, and thereafter, two kinds of speed operations are performed. As described, part of the resin does not protrude from the outer periphery of the mold until the outermost periphery of the resin reaches the outer periphery of the mold in all directions. After being spread, the resin uniformly protrudes from the outer peripheral portion of the mold by the approach operation at the first speed to form a resin layer. in this case,
Since the amount of the resin protruding is also controlled, as described above, the problem that the resin protrudes beyond a predetermined portion due to the continuous approaching operation is prevented.

The circle of 80% is set so that if the diameter exceeds 80% of the diameter of the optical surface of the mold, the above-mentioned inconvenience may occur even if intermittent operation is performed thereafter. If the value is lower than this, the period of the intermittent operation or the like becomes longer, and the tact time of manufacturing the optical element becomes longer.

The time to reach the 80% circle is determined by repeating experiments after designing the optical element.

The method for manufacturing an optical element according to claim 11 of the present invention is the method for manufacturing an optical element according to claim 9 or claim 10, wherein the diameter of the optical surface of the mold is smaller than a desired resin layer diameter. It is characterized by being small.

In the ninth or tenth aspect of the present invention, the resin layer may be formed so as to protrude uniformly from the outer periphery of the mold. In this case, the diameter of the optical surface of the mold naturally depends on the desired resin layer. It must be smaller than the diameter.

According to a twelfth aspect of the present invention, in the method of manufacturing an optical element, an energy-curable resin is supplied to an optical surface of a mold or a molding surface of a substrate of an optical element, and the mold and the optical element substrate are moved relative to each other. Forming a desired resin layer between the mold and the optical element substrate by spreading the resin by close proximity to each other, irradiating the resin layer with energy to cure the resin layer, and then setting the cured resin In the method for manufacturing an optical element for separating a layer and a mold, an outer peripheral shape of the mold optical surface is a non-rotationally symmetric shape, and the mold and the optical element after the mold optical surface and a resin are brought into contact with each other. The relative approach operation of the base material is a continuous approach operation, followed by an intermittent operation in which the stop and the approach at the first speed are repeated, or an approach at a second speed lower than the first speed. It is a two-speed operation that repeats the approach at the first speed And wherein the door.

The shape of the optical element substrate is circular, the resin layer to be formed is a non-rotational axis symmetrical shape such as a rectangle, and the portion of the optical element substrate on which the resin layer is not formed has a predetermined purpose, for example, an optical element. In the case where the optical element is used as a part to be held by another member, the outer peripheral shape of the optical surface of the mold is made to be a non-rotationally symmetrical shape, and an optical element having a non-rotationally symmetrically shaped resin layer is provided by the present invention. It can be manufactured according to.

Further, in the case where the outer peripheral shape of the optical surface of the mold is non-rotationally symmetric, the outer peripheral shape of the optical element substrate is also non-rotationally symmetrical in accordance with the resin layer formed thereby. be able to. For example, when an optical element is manufactured by forming a rectangular resin layer on the molding surface of a rectangular optical element substrate, the optical element can be made more compact than when the optical element substrate is circular. .

Further, it is preferable that the optical element substrate and the mold are continuously approached to each other until a part of the step in which the mold optical surface comes into contact with the resin layer and the resin is spread. As in the case of the above, it is for shortening the tact time of manufacturing the optical element.

The intermittent operation or the two-speed operation after the continuous approach operation has already been described in the description of the first aspect of the present invention, and a duplicate description will be omitted.

Further, a method of forming a non-rotationally symmetric resin layer on a molding surface of an optical element substrate is also described.
Since the present invention has been described in detail with reference to FIG. 3, a duplicate description will be omitted.

Although FIG. 3 illustrates a case where both the outer peripheral shape of the optical element substrate and the outer peripheral shape of the mold are rectangular shapes that are non-rotationally symmetric, the outer peripheral shape of the optical element substrate is rotated. Even in the case of a symmetrical circular shape, an optical element can be manufactured similarly. This is because the shape of the resin layer to be formed is determined by the outer shape of the mold, and no particular inconvenience occurs even if the outer shape of the optical element substrate is changed to a circle in FIG.

The method for manufacturing an optical element according to claim 13 of the present invention is the method for manufacturing an optical element according to claim 12, wherein the center of curvature of the molding surface on which the resin layer of the optical element substrate is formed, and the molding surface When a straight line connecting the centers of curvature of the non-molding surfaces on the back side opposite to each other is set as the rotationally symmetric axis, the continuous approaching operation is performed by setting a point on the mold optical surface that is in contact with the intersection of the resin layer surface and the rotationally symmetric axis. The mold and the optical element base have the same center as the inscribed circle with respect to the outer peripheral shape of the mold optical surface and have a diameter from the inside of 80% of the inscribed circle until at least a portion of the resin protrudes. It is characterized by a material approaching movement.

In the present invention as well, in order to avoid a problem that the outermost peripheral portion of the resin protrudes beyond the outer peripheral portion of the optical element substrate as in the tenth aspect, the resin is pushed out by a continuous approaching operation. When the outermost peripheral portion of the resin reaches the circumference of a circle having a diameter equivalent to 80% of the diameter of the inscribed circle with respect to the outer peripheral shape of the mold optical surface, the approach operation of the mold and the optical element base material is performed. An intermittent operation or a two-speed operation has the effect of controlling the spread of the resin. The intermittent operation or the two-speed operation is performed when a part of the resin has the diameter of 8
The reason and the like that are made until the protrusion protrudes from the inside of the circle having the diameter of the split size are the same as those described for the invention of claim 10, and therefore, the description thereof is omitted.

The reason why the radius of the inscribed circle is the shortest distance from the center of the circle to the outer periphery of the non-rotationally symmetrical shape is based on the inscribed circle with respect to the outer peripheral shape of the mold optical surface. If the resin does not protrude beyond the circumference of the inscribed circle, the resin does not protrude beyond the outer periphery of the optical element base material.

A method for manufacturing an optical element according to claim 14 of the present invention is the method for manufacturing an optical element according to claim 12 or 13, wherein the outer peripheral shape of the optical element substrate is non-rotationally symmetric. It is characterized by.

The most frequently used optical element is a lens, which is generally circular. However, when the lens is applied to a camera or the like, the lens does not need to be circular because the film is rectangular. For example,
When the outer peripheral shape of the optical element substrate is circular, a part of the circumference is cut off along two parallel straight lines equidistant from the center of the circle to form two chords, and the two chords are formed. Even if it is a so-called oval shape connected by an arc, its optical characteristics are not impaired. By forming a resin layer having an aspherical shape on such an optical element substrate by the method of the present invention to form a lens,
If the present invention is applied to a camera or the like, the camera or the like can be further reduced in size because it has a compact non-rotationally symmetric shape with a part of the circumference cut off.

The non-rotationally symmetrical shape in the present invention can be selected from the above-mentioned oval shape, a shape obtained by deleting a part or a plurality of portions of a circular outer periphery, a polygon, an ellipse, and the like according to the needs of each. Thus, the scope of the invention can be expanded.

A method for manufacturing an optical element according to claim 15 of the present invention is the method for manufacturing an optical element according to any one of claims 1, 9 and 12, wherein the energy-curable resin has a viscosity of 20,000 cps or less. There is a feature.

Claims 1, 9 and 12 disclose means for controlling the range in which the resin is spread by intermittent operation or two-speed operation of the mold and the optical element base material to solve the problem. However, in order to solve the problem by these operations, the action of the surface tension of the resin is applied. In order to form a resin layer having a desired shape by the above-described operation, the action of an appropriate surface tension of the resin is indispensable. However, in the case of an energy-curable resin, in order to make the above-mentioned operation effective, The inventors have found through experiments and the like that the viscosity is limited.

In the case of these types of resins, if the viscosity of the resin exceeds 20,000 cps, the surface tension is not sufficient even if the above operation is performed, so that a desired resin layer cannot be obtained. That is, if the viscosity of the resin is too high, the surface tension does not act sufficiently when the resin is spread, and therefore, a problem such as the resin protruding beyond a predetermined range occurs. Therefore, in the present invention, the range of the viscosity of the resin is limited as described above.

[0088]

Embodiments of the present invention will be specifically described below with reference to the drawings. In each of the embodiments, the same elements are denoted by the same reference numerals and correspond to each other.

(Embodiment 1) Embodiment 1 of the present invention will be described with reference to FIGS. FIG. 4 is a view showing a state in which the resin is supplied to the molding surface of the optical element base material, FIG. 5 is a view showing a state in which the resin is brought close to the optical element base material and the resin is spread, and FIG. 6 is a mold. 7 shows a state in which the resin is pushed out to the entire outer periphery of FIG. 7, FIG. 7 shows a state in which the resin layer is formed, and FIGS.
FIG. 3 is a diagram showing a peeled state between a resin layer and a mold.

In this embodiment, a circular resin layer is formed on a glass substrate as an optical element substrate having a rotationally symmetrical shape having a rotationally symmetric axis by using a metal mold having a mold optical surface having a rotationally symmetrical shape. Formed. As shown in FIG. 4, the glass substrate 22 has a concave surface having a radius of curvature of 100 mm on the surface on which the resin layer is mounted (hereinafter, molding surface) 22a, and a surface on which the resin layer is not mounted (the back surface facing the molding surface 22a). 22b is a concave surface having a radius of curvature of 50 mm, and the diameters are the molding surface 22a and the non-molding surface 2b.
22 mm about a straight line (hereinafter, rotationally symmetric axis) A connecting the centers of curvature of 2b and the molding surface 22 on the rotationally symmetric axis A
The distance between a and the non-molded surface 22b is 2 mm. Further, a predetermined amount of resin 25 is supplied onto the molding surface 22a of the glass base material 22. Resin 25 has a viscosity of 10
000 cps.

As the glass substrate 22 in the present embodiment, an optical glass having a trade name of “PBL28” (manufactured by OHARA Co., Ltd.) is used.
-201 "(manufactured by Mitsubishi Rayon Co., Ltd.).

The mold 21 is disposed above the glass substrate 22 and has a center axis the same as the rotational symmetry axis A and a diameter of 20 mm.
is divided into an inner mold 21a and an outer mold 21b which are vertically movable at a position of 24 mm and a diameter of 24 mm. The outer mold 21b is 0.2 mm farther than the glass base 22 than the inner mold 21a. Are fitted in such a manner that there is a step. The inner die 21a has a resin pressing surface 21 as a mold optical surface.
c, and the resin pressing surface 21 c and the molding surface 22 a of the glass substrate 22 are in a state of being opposed to each other.

From this state, the mold 21 is moved to the glass substrate 22.
At a speed of 0.5 mm / sec to the molding surface 22a in the space formed by the resin pressing surface 21c of the inner mold 21a and the molding surface 22a of the glass base material 22.
The resin 25 supplied above is gradually spread. Then, as shown in FIG.
80% of the diameter of the resin pressing surface 21c of FIG.
This operation is continued until the operation reaches the portion indicated by the broken line in FIG. At this time, on the rotational symmetry axis A, the distance between the mold 21 and the glass substrate 22 is 0.28 mm.

Next, the mold 21 is intermittently brought close to the glass substrate 22. This intermittent approach is 0.1 mm / s
The approach of 3 μm at the speed of ec and the stop of 0.5 sec are repeated 20 times. During this series of operations, a part of the outermost peripheral portion of the resin 25 reaches the outermost peripheral portion of the inner mold 21a.
The resin 25 does not protrude outward from this position, and even when the mold 21 is brought close to the glass base material 22, the resin 25 is filled into the portion that has not reached the outermost peripheral portion of the inner mold 21a. At the end of this series of operations, the distance between the mold 21 and the glass substrate 22 on the rotational symmetry axis A is 0.22 mm.

In this state, the mold 21 is further intermittently brought closer to the glass substrate 22. This intermittent approach is 2 μm approach at a speed of 0.05 mm / sec and 1
The stop of sec is repeated 10 times. During this series of operations, there is a moment when the resin 25 fills the entire surface of the resin pressing surface 21c of the inner mold 21a as shown in FIG. Then, by the subsequent approaching operation, the resin 25 uniformly protrudes from the entire circumference of the inner mold 21a, and a desired resin layer 23 as shown in FIG. 7 is formed.

Next, the entire surface of the resin layer 23 is irradiated with ultraviolet rays from below the glass substrate 22 by means (not shown) to cure the resin layer 23. As a result, an adhered body in which the mold 21, the resin layer 23, and the glass substrate 22 are integrated is formed.

Next, the outer mold 21b is raised, and the outer mold 21b is peeled off from the resin layer 23 as shown in FIG. On this occasion,
Since the contact area between the outer mold 21b and the resin layer 23 is smaller than the contact area between the inner mold 21a and the resin layer 23, it can be easily peeled off. Thereafter, as shown in FIG.
1b is moved in a direction to approach the glass substrate 22, so that the optical element 26 is pressed from the resin pressing surface 21c of the inner mold 21a.
(Adhesive body in which glass substrate 22 and resin layer 23 are integrated)
Is peeled off.

According to the embodiment of the present invention, it is possible to obtain an optical element having a good coaxiality of the outer diameter of the resin layer 23 with respect to the outer diameter of the glass substrate 22. Further, an optical element having good roundness of the outer shape of the resin can be obtained.

That is, in the present embodiment, the distance between the mold 21 and the glass substrate 22 on the axis of rotational symmetry A, that is, until the thickness of the resin 25 becomes 0.28 mm, the resin 25 is continuously approached. And then, as the first speed, 2
Speed, 0.1mm / sec and 0.05mm / sec
Spread the resin 25 with 0.5sec and 1s respectively
The desired resin layer 23 is obtained by the intermittent approaching operation of the mold 21 and the glass base material 22 combined with stopping of ec,
By increasing the combination of the first speed and the stop, the resin thickness can be controlled more minutely and precisely.

For example, until the thickness of the resin 25 becomes 0.3 mm, the resin 25 is spread by a continuous approaching operation of the mold 21 and the glass base material 22.
4μm approach and 0.3sec at a speed of mm / sec
Is repeated 10 times, and secondly, 0.1 mm / sec
3 μm approach and 0.5 sec stop by the speed of c
Repeat 0 times, thirdly, approach 2 μm at 0.08 mm / sec speed and stop 0.8 sec 10 times, and finally 1 μm at 0.05 mm / sec speed
Mold 21 that repeats approaching and stopping for 1.2 sec 10 times
When the intermittent approaching operation of the glass substrate 22 and the glass substrate 22 is performed, the takt time is slightly longer due to the approach at the four different first speeds and the stop combined therewith.
From the thicker 0.3 mm stage,
Since the thickness 5 can be controlled, it is possible to obtain a highly accurate optical element having good coaxiality and roundness of the outer shape.

(Embodiment 2) The embodiment of the present invention
In the first embodiment of the present invention, the operation until the distance between the mold 21 and the glass substrate 22 becomes 0.28 mm is the same as that in the first embodiment of the present invention. It will be described with reference to FIG.

First, when the distance between the mold 21 and the glass base 22 is 0.28 mm (see FIG. 5), the mold 21 is brought closer to the glass base 22 by two-speed operation. This approach operation is performed at a speed of 2.5 μm at a speed of 0.1 mm / sec.
0.5 due to the approach of m and the speed of 0.025 mm / sec
The approach of μm is alternately repeated 20 times. In the middle of this series of operations, a part of the outermost peripheral portion of the resin 25 reaches the outermost peripheral portion of the inner mold 21a, but does not protrude outside this position. Even when approached, the resin 25 is filled into the portion that has not reached the outermost peripheral portion of the inner mold 21a. The reason for this is that the resin 25, which is about to protrude from the mold 21 when approaching at a speed of 0.1 mm / sec, approaches the inside of the mold 21 again when approaching at a speed of 0.025 mm / sec. To try to return. At the end of this series of operations, the distance between the mold 21 and the glass substrate 22 on the axis of rotational symmetry A is 0.2
It is 2 mm.

From this state, the mold 21 is moved closer to the glass substrate 22 by the two-speed operation. This approach operation alternately repeats 10 times of approach of 1 μm at a speed of 0.05 mm / sec and approach of 1 μm at a speed of 0.025 mm / sec. During this series of operations, as shown in FIG. 6, the resin 25 is pressed against the resin pressing surface 2 of the inner mold 21a.
There is a moment when the entire surface of 1c is filled. Then, by the subsequent approaching operation, the resin 25 protrudes uniformly from the entire surface of the resin pressing surface 21c of the inner mold 21a, and a desired resin layer 23 as shown in FIG. 7 is formed.

The subsequent operation is the same as in the first embodiment of the present invention, as shown in FIGS.

The effects of the embodiment of the present invention are the same as those of the first embodiment of the present invention.

That is, in the present embodiment, the distance between the mold 21 and the glass substrate 22 on the axis of rotational symmetry A, that is, until the thickness of the resin 25 becomes 0.28 mm, the resin 25 is continuously approached. And then, as the first speed, 2
Speed, 0.1mm / sec and 0.05mm / sec
To spread the resin 25, which is sufficiently slower than the first speed.
The desired resin layer 23 is obtained by the two-speed operation of the mold 21 and the glass substrate 22 in combination with the approach at the second speed of 025 mm / sec, but the first speed and the second speed close to the stop are obtained. By increasing the combination of speeds, the resin thickness 3 can be controlled more minutely and precisely.

For example, until the thickness of the resin 25 becomes 0.3 mm, the resin 25 is pushed out by a continuous approaching operation of the mold 21 and the glass base material 22.
4 μm approach and 0.025 m at a speed of mm / sec
1 μm approach combination at a second speed of m / sec
0 times, secondly, a combination of 2 μm approach at a speed of 0.08 mm / sec and 1 μm approach at a second speed of 0.025 mm / sec was repeated 10 times, and finally a combination of 0.05 mm / sec. 0.5 μm approach by speed and 0.5 μm at second speed of 0.025 mm / sec
m, the approaching operation by the two kinds of speed operations of the mold 21 and the glass base material 22 is performed three times.
A close approach to a stop with two different first speeds and a combined second speed with it will slightly increase the takt time, but the resin 25 will be 0.3 m thicker.
Since the thickness of the resin 25 can be controlled more minutely from the stage of m, it is possible to obtain a highly accurate optical element having better coaxiality and roundness of the outer shape.

(Embodiment 3) Embodiment 3 of the present invention will be described with reference to FIGS. In the present embodiment,
A non-rotationally symmetrical resin layer was formed on a glass substrate as an optical element substrate having a non-rotationally symmetrical shape using a mold whose mold optical surface had a non-rotationally symmetrical shape.

FIG. 10 is a side view of the glass substrate 32. As shown in the figure, the glass substrate 32 has a surface (hereinafter referred to as a molding surface) 32a on which the resin layer is mounted, having a radius of curvature. 100
mm, the surface on which the resin layer is not placed (the non-molding surface on the back side facing the molding surface 32a) 32b has a radius of curvature of 50 mm,
The distance between the molding surface 32a and the non-molding surface 32b on a straight line (hereinafter, rotationally symmetric axis) B connecting the centers of curvature of the molding surface 32a and the non-molding surface 32b is 2 mm, and both surfaces are concave.

FIG. 11 shows an xy perpendicular to the rotational symmetry axis B passing through the intersection of the rotational symmetry axis B and the molding surface 32a of the glass substrate 32.
After the flat surface is provided, the outer peripheral portion of the molding surface 32a is
2 shows a shape projected on an xy plane in parallel with FIG. Glass substrate 3
Reference numeral 2 denotes two arcs 32 each having a diameter of 25 mm except for a range of 45 degrees above and below the x axis on both the positive side and the negative side of the x axis.
It has a c-shape, and a range of 45 degrees vertically on both the positive side and the negative side with respect to the x-axis is a constant chord parallel to the y-axis with an absolute value of the x-coordinate connecting the end points of the arc 32c of about 8.84 mm. It has a 32d shape.

The glass substrate 32 is obtained by forming a circular outer shape symmetrical with respect to the rotation axis and then cutting a part of the outer shape to form a portion corresponding to the string 32d.

Further, as shown in FIG.
On the second molding surface 32a, a resin 35 is supplied in a substantially rotationally symmetric shape. The rotation center of the resin 35 supplied rotationally symmetrically substantially coincides with the rotational symmetry axis B, and the supply amount of the resin 35 is assumed to be obtained in advance by examination.

As shown in FIG. 12, the mold 31 has a resin pressing surface 31a as an optical surface for forming a desired resin layer surface shape. This mold 31 is used for the resin pressing surface 3.
The resin pressing surface 31a is located on the rotational symmetry axis B, and can be freely moved in a direction parallel to the rotational symmetry axis B. As shown in FIG. 13, the shape of the outer peripheral portion of the resin pressing surface 31 a of the mold 31 projected on the xy plane in parallel to the rotational symmetry axis B is:
Except for the range of 45 degrees above and below the x-axis, 2
In the range of 45 degrees above and below the x-axis on both the positive and negative sides of the x-axis, the absolute value of the x-coordinate connecting the end points of the arc 31c is about 7.78 mm and is parallel to the y-axis. It has a constant chord (straight line) 31d shape. That is, the mold 31 has a shape substantially similar to the outer peripheral shape of the glass substrate 32.

Next, a process of forming a resin layer 33 having a desired shape in a space formed by the resin pressing surface 31a of the mold 31 and the molding surface 32a of the glass substrate 32 will be described with reference to FIGS. I do.

As shown in FIG. 14, after the positions of the strings 32d and 31d of the glass substrate 32 and the mold 31 are aligned, the mold 31 is moved at a speed of 0.5 mm / sec with respect to the glass substrate 32. To gradually spread the resin 35 in the space defined by the resin pressing surface 31a of the mold 31 and the molding surface 32a of the glass substrate 32.

Then, as shown in FIG. 15, the outermost peripheral portion of the resin 35 is a circle whose center is centered on the outer shape of the resin pressing surface 31a of the mold 31 and whose diameter is inscribed in the resin pressing surface 31a of the mold 31. This operation is continued until a circle of 0.8 times (a broken line portion in FIG. 15) is reached. At this time, on the rotational symmetry axis B, the resin pressing surface 31a of the mold 31 and the glass substrate 3
The distance between the second molding surfaces 32a is 0.28 mm.

Next, the mold 31 is intermittently brought close to the glass substrate 32. This intermittent approach is 0.1 mm / s
The approach of 3 μm at the speed of ec and the stop of 0.5 sec are alternately repeated 20 times. During this series of operations, a part of the outermost peripheral portion of the resin 35 reaches the outermost peripheral portion of the resin pressing surface 31a of the mold 31, but does not protrude outside this position. Even when approaching the glass substrate 32,
The resin 35 is filled into a portion of the resin pressing surface 31a of the mold 31 that is not filled with the resin. When this series of operations is completed, the resin pressing surface 31a of the mold 31 and the molding surface 3
The interval between 2a is 0.22 mm.

In this state, the mold 31 is further intermittently brought closer to the glass substrate 32. This intermittent approach is 2 μm approach at a speed of 0.05 mm / sec and 1
The stop of sec is repeated 10 times. During this series of operations, there is a moment when the resin 35 is filled over the entire surface of the resin pressing surface 31a of the mold 31. Then, by the subsequent approaching operation, the resin 35 uniformly protrudes from the entire circumference of the resin pressing surface 31a of the mold 31, and the desired resin layer 3 as shown in FIG.
3 is formed.

Next, the entire surface of the resin layer 33 is irradiated with ultraviolet rays from below the glass substrate 32 by means (not shown) to cure the resin layer 33. As a result, an adhered body in which the mold 1, the resin layer 33, and the glass substrate 32 are integrated is formed.

Next, as shown in FIG. 17, a load is applied to one portion of the outer peripheral portion of the glass base 32 from above to below by the member 34. Then, Figure 1
As shown in FIG. 8, the optical element 36 (adherent body in which the glass substrate 32 and the resin layer 33 are integrated) is peeled off from the resin pressing surface 31 a of the mold 31.

According to the embodiment of the present invention, even if the outer shape of the glass substrate 32 is non-rotationally symmetric, the resin 3
It is possible to obtain an optical element having the resin layer 33 in which 5 does not protrude from the molding surface 32a of the glass substrate 32.

In the present embodiment, after the thickness of the resin 35 is expanded to 0.28 mm on the axis of rotational symmetry B, the resin layer 33 is intermittently moved by the mold 31 and the glass substrate 32. However, the desired resin layer 33 can be formed by two-speed operation instead of the intermittent operation.

That is, after the thickness of the resin becomes 0.28 mm, the mold 31 is brought closer to the glass substrate 32 by the two-speed operation. This approach operation is performed at 0.1 mm / sec.
2.5 μm approach and 0.025 mm / s with speed c
The approach of 0.5 μm at the speed of ec is alternately repeated 20 times. During this series of operations, a portion 15a of the outermost peripheral portion of the resin 35 reaches the outermost peripheral portion of the resin 35, but does not protrude outside this position. Even when approached, the resin 35 fills the portion of the mold 31 that has not reached the outermost periphery of the resin pressing surface 31a.

From this state, the mold 31 is moved closer to the glass substrate 32 by the two-speed operation. This approach operation alternately repeats 10 times of approach of 1 μm at a speed of 0.05 mm / sec and approach of 1 μm at a speed of 0.025 mm / sec. During this series of operations, there is a moment when the resin 35 is filled over the entire surface of the resin pressing surface 31a of the mold 31. And by the subsequent approach operation,
The resin 35 is uniformly formed from the entire circumference of the resin pressing surface 31a of the mold 31.
Then, a desired resin layer 33 as shown in FIG. 16 is formed. Therefore, even if the outer shape of the glass substrate 32 is non-rotationally symmetric, the resin 35 is
An optical element that does not protrude from the molding surface 32a can be obtained.

In this embodiment, the glass substrate 32
The method of manufacturing an optical element in the case where both of the molds 31 are non-rotationally symmetrical shapes has been described. However, the glass substrate has a circular rotationally symmetrical shape, and the glass substrate has a non-rotationally symmetrical shape. An optical element having a non-rotationally symmetrical resin layer 33 formed by the mold 31 can be manufactured.

[0126]

As described above, according to the first aspect of the present invention,
According to the method for manufacturing an optical element according to the above, it is possible to obtain an optical element having good coaxiality of the outer shape of the resin with respect to the outer shape of the optical element substrate. Further, an optical element having good roundness of the outer shape of the resin can be obtained. Further, even if the outer shape of the optical element substrate is non-rotationally symmetric, an optical element in which the resin does not protrude from the molding surface of the optical element substrate can be obtained.

According to the method of manufacturing an optical element according to the second aspect of the present invention, the spread of the entire resin can be made small, and an optical element having a desired spread can be obtained under ordinary production conditions.

According to the method for manufacturing an optical element according to the third and fourth aspects of the present invention, the resin layer can be formed so as to protrude a uniform distance from the outer periphery of the optical surface of the mold.

According to the method of manufacturing an optical element according to claims 5 to 8 of the present invention, the spread of the resin can be controlled when the resin is spread.

According to the method of manufacturing an optical element according to the ninth aspect of the present invention, it is possible to obtain an optical element having a good coaxiality of the outer shape of the resin with respect to the outer shape of the optical element substrate.
Further, an optical element having good roundness of the outer shape of the resin can be obtained.

According to the optical element manufacturing method of the tenth and eleventh aspects of the present invention, the resin layer can be formed on the entire optical surface of the mold without protruding the resin from the outer peripheral portion of the mold. . Further, after the resin is spread over the entire optical surface of the mold, the resin can be uniformly formed from the outer peripheral portion of the mold to form a resin layer, and the amount of the resin protruding can be controlled.

According to the optical element manufacturing method of the twelfth aspect of the present invention, it is possible to obtain an optical element having a non-rotationally symmetric resin layer formed on a rotation axis symmetric optical element substrate. it can.

According to the method of manufacturing an optical element according to the thirteenth aspect of the present invention, the resin does not protrude from the outer peripheral portion of the mold having the mold optical surface having a non-rotational axis symmetrical shape. A resin layer can be formed over the entire surface. further,
After the resin is spread over the entire surface of the mold optical surface, the resin layer can be formed by uniformly protruding the resin from the outer periphery of the mold.

According to the method of manufacturing an optical element according to the fourteenth aspect of the present invention, it is possible to obtain an optical element having a non-rotationally symmetric resin layer formed on a non-rotationally symmetric optical element substrate. Thus, an optical element having a desired shape as required can be manufactured.

According to the method of manufacturing an optical element according to the fifteenth aspect of the present invention, when spreading the resin, the resin layer can be formed by giving an appropriate surface tension to the outer periphery of the resin.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram illustrating a method for manufacturing an optical element of the present invention.

FIG. 2 is a diagram schematically showing an intermittent operation and a two-speed operation of the present invention.

FIG. 3 is a view schematically showing a method for manufacturing an optical element of the present invention.

FIG. 4 shows Embodiment 1 of the present invention, in a state where a resin is supplied to a glass base material.

FIG. 5 shows the first embodiment of the present invention, in a state where the resin is being spread.

FIG. 6 shows the first embodiment of the present invention, in a state where the resin is pushed out to the outer periphery of the mold.

FIG. 7 shows the first embodiment of the present invention, in a state where a resin layer is formed.

FIG. 8 shows the first embodiment of the present invention, in which the resin layer and the mold are separated.

FIG. 9 shows Embodiment 1 of the present invention, and shows a state in which the resin layer and the mold are separated.

FIG. 10 shows the second embodiment of the present invention, and is a diagram of a glass substrate viewed from the side.

FIG. 11 is a view of the glass substrate as viewed from above in FIG. 10;

FIG. 12 shows the second embodiment of the present invention and is a view of a mold as viewed from the side.

FIG. 13 is a view as viewed from below in FIG. 12;

FIG. 14 shows the second embodiment of the present invention, in a state where the resin is pushed and spread.

FIG. 15 shows the second embodiment of the present invention, and shows a state where the resin is spread.

FIG. 16 shows the second embodiment of the present invention, in which a resin layer is formed.

FIG. 17 shows the second embodiment of the present invention, in which the resin layer and the mold are separated.

FIG. 18 shows the second embodiment of the present invention, in which the resin layer and the mold are separated.

[Explanation of symbols]

 Reference Signs List 1,11 Base material 1a, 11a Molding surface 2,12 Mold 2a, 12a Mold optical surface 3,13 Resin layer 5,15 Resin 21,31 Mold 21a Inner mold 21b Outer mold 21c, 31a Resin pressing surface 22, 32 Glass substrate 22a, 32a Molding surface 23, 33 Resin layer 25, 35 Resin 26, 36 Optical element

Claims (15)

[Claims] An energy-curable resin is supplied to an optical surface of a mold or a molding surface of an optical element base material, and the resin is spread out by relatively approaching the mold and the optical element base material. After forming a desired resin layer between the and the optical element substrate, and curing the resin layer by irradiating energy to the resin layer,
In a method of manufacturing an optical element for separating a cured resin layer and a mold, a relative approaching operation between the mold and the optical element substrate after the optical surface of the mold and the resin are brought into contact with each other is performed at a first speed. Intermittent operation that repeats approach and stop at a distance, or two speed operation that repeats approach at the first speed and approach at a second speed lower than the first speed. Manufacturing method of optical element. 2. The method according to claim 1, wherein the first speed includes at least two or more speeds in a range faster than the second speed, and each speed and an intermittent operation including a stop or each speed and a second speed. 2. The method for manufacturing an optical element according to claim 1, wherein a two-speed operation including a speed is performed a plurality of times for at least one of the first speeds. 3. The method of manufacturing an optical element according to claim 1, wherein said intermittent operation repeats approaching and stopping at said first speed three times or more. 4. The optical element according to claim 1, wherein the two-speed operation repeats the approach at the first speed and the approach at the second speed three times or more. Production method. 5. The relative approach distance between the mold and the optical element substrate at the first speed gradually decreases as the distance between the mold and the optical element substrate decreases. The method for producing an optical element according to claim 1 or 2, wherein 6. The relative approach speed of the mold and the optical element substrate at the first speed gradually decreases as the distance between the mold and the optical element substrate decreases. The method for producing an optical element according to claim 1 or 2, wherein 7. The time for stopping the relative approach between the mold and the optical element base material gradually increases as the distance between the mold and the optical element base material decreases. 3. The method for manufacturing an optical element according to 1 or 2. 8. The optical element according to claim 1, wherein the approach operation time at the second speed gradually increases as the distance between the mold and the optical element base material decreases. Manufacturing method. 9. An energy-curable resin is supplied to an optical surface of a mold or a molding surface of an optical element base material, and the resin is pushed and spread by relatively bringing the mold and the optical element base material close to each other. After forming a desired resin layer between the and the optical element substrate, and curing the resin layer by irradiating energy to the resin layer,
In a method for manufacturing an optical element for separating a cured resin layer and a mold, an outer peripheral shape of the mold optical surface is a rotational axis symmetric shape, and the mold optical surface and the mold after contact with a resin are The relative approach operation of the optical element substrate is a continuous approach operation, followed by an intermittent operation of repeating stop and approach at a first speed, or an approach at a second speed lower than the first speed. And an approach at the first speed. 10. The continuous approaching operation is performed in such a manner that the center is the same as the optical surface of the mold and the diameter of the mold and the optical part are at least partly protruded from the inside of an 80% circle of the optical surface of the mold. The method for manufacturing an optical element according to claim 9, wherein the operation is an approaching operation of the element substrate. 11. The method according to claim 9, wherein a diameter of the optical surface of the mold is smaller than a desired diameter of the resin layer. 12. An energy-curable resin is supplied to an optical surface of a mold or a molding surface of an optical element substrate, and the resin is spread out by relatively approaching the mold and the optical element substrate. And forming a desired resin layer between the optical element substrate,
After the resin layer is cured by irradiating energy to the resin layer, the cured resin layer and the mold are separated from each other in an optical element manufacturing method, wherein the outer peripheral shape of the mold optical surface is a non-rotationally symmetric shape. Yes,
The relative approaching operation of the mold and the optical element substrate after the mold optical surface and the resin come into contact with each other is an intermittent operation in which a continuous approaching operation and a subsequent stop and approach at a first speed are repeated. Or a two-speed operation in which approach at a second speed lower than the first speed and approach at the first speed are repeated. 13. When the straight line connecting the center of curvature of the molding surface on which the resin layer of the optical element substrate is formed and the center of curvature of the non-molding surface on the back side facing the molding surface is defined as the rotationally symmetric axis, the continuous approach The operation is the same as the inscribed circle with respect to the outer peripheral shape of the mold optical surface centered on a point on the mold optical surface that comes into contact with the intersection of the resin layer surface and the rotational symmetry axis, and the diameter is the inscribed circle. 13. The method for manufacturing an optical element according to claim 12, wherein the approach operation is performed between the mold and the optical element base until at least a portion of the resin protrudes from the inside of the 80% circle. 14. The optical element substrate according to claim 12, wherein an outer peripheral shape of the optical element substrate is a non-rotationally symmetrical shape.
A manufacturing method of the optical element described in the above. 15. The method for manufacturing an optical element according to claim 1, wherein the viscosity of the energy-curable resin is 20,000 cps or less.