JP5731840B2 - Molding method of molded products - Google Patents

Description

The present invention relates to a method for molding a molded product , for example, a method for obtaining a molded product by using a mold and curing an ultraviolet curable resin or the like.

  Conventionally, a molding material such as an uncured ultraviolet curable resin is supplied to a mold (for example, a lower mold), and the supplied ultraviolet curable resin is cured to obtain a molded product (for example, a lens assembly).

  In addition, after the ultraviolet curable resin is cured, it is necessary to release (release) the cured ultraviolet curable resin (molded product) from the upper mold and the lower mold. Therefore, a mold release agent is applied to the mold in order to make it easy to separate the molded product from the mold (for example, see Patent Document 1).

JP-A-8-117956

  By the way, when releasing the mold, for example, by changing the shape of the lens portion of the lens assembly formed by the upper die and the shape of the lens portion of the lens assembly formed by the lower die, the upper die is changed. When separated from the lower mold, the cured ultraviolet curable resin (lens assembly) can always remain in the lower mold.

  However, even if the lens assembly remains on the lower mold, the lens assembly remaining on the lower mold must be separated from the lower mold (must be released from the lower mold).

  In order to separate the lens assembly from the lower mold, it is possible to rely on human hands, vacuum-adsorb the lens assembly, insert a scraper between the lens assembly and the lower mold, or between the lens assembly and the lower mold. A method (or a combination of each method) in which compressed air is introduced or an ejector pin is used can be employed.

  However, even if a release agent is used in combination, the above-described method may not allow the lens assembly to be separated from the lower mold efficiently and reliably.

The present invention has been made in view of the above problems, and a molded product molding method capable of easily separating a molded product from a mold when a molded product is obtained by curing a molding material using a mold. The purpose is to provide.

The invention described in claim 1 includes a molding material supply step for supplying an uncured molding material to the lower mold, a part of the uncured molding material supplied in the molding material supply step, and other parts. In a mode in which the upper mold and the lower mold are separated from between the upper mold and the lower mold, or so as to protrude from the uncured molding material supplied in the molding material supply step, or A release member installation step of installing a release member in an aspect that is attached to the upper mold or the lower mold, or in an aspect that is attached to both the upper mold and the lower mold, and the release After the mold release member is installed in the mold member installation process, the molding material curing process for curing the molding material, and after the molding material is cured in the molding material curing process, the protruding mold release member Pull the cured molding material away from the mold by pulling A method of molding a molded article having a mold process.

  According to the present invention, when a molded product is obtained by curing a molding material using a mold, the molded product can be easily separated from the mold.

It is a figure which shows the structure of a lens assembly, (a) is a top view of a lens assembly, (b) is II sectional drawing in (a). It is a figure which shows the shaping | molding method of a lens assembly. It is a figure which shows the shaping | molding method of a lens assembly. It is a figure which shows the shaping | molding method of a lens assembly. It is a figure which shows the shaping | molding method of a lens assembly. It is a figure which shows the modification of a lens assembly, (a) is a partial top view of a lens assembly, (b) is VI-VI sectional drawing in (a). It is a figure which shows the modification of a lens assembly, (a) is a partial top view of a lens assembly, (b) is VII-VII sectional drawing in (a). It is a figure which shows the modification of a lens assembly, (a) is a partial top view of a lens assembly, (b) is a VIII-VIII sectional drawing in (a). It is a figure which shows the modification of a lens assembly, and is a figure corresponding to (b) of FIG. It is a figure which shows the modification of a lens assembly, and is a figure corresponding to (b) of FIG.

  A lens assembly (wafer lens) 1 according to an embodiment of the present invention includes a main body 2 and a release member 4 as shown in FIG. The main body 2 is made of a material such as a transparent resin such as a cured ultraviolet curable resin, and includes a lens part (main part) 3 and a peripheral part 5.

  The lens unit 3 is a part that becomes a product or a semi-finished product, and exhibits a function as a product or a semi-finished product. The peripheral portion 5 is a portion that is connected to the lens portion 3 and is integrally formed with the lens portion 3. Moreover, the peripheral part 5 hardly exhibits the function as a product or a semi-finished product. Further, after the lens assembly 1 (main body 2) is molded, the entire peripheral part 5 may be used together with the lens part 3, or a part of the peripheral part 5 may be used together with the lens part 3. The peripheral part 5 may be separated from the lens part 3 in some cases.

  More specifically, the main body 2 includes a plate-shaped lens main body 7, a plurality of convex portions 9 having a spherical crown shape, and a plurality of convex portions 11 having a spherical crown shape. The lens body 7 is formed in a disc shape, for example. The convex portions 9 and 11 (patterns formed by the molds M1 and M2 shown in FIG. 2 and the like) are provided at predetermined intervals on both surfaces in the thickness direction of the lens main body portion 7.

When the lens assembly 1 (lens main body portion 7) is viewed from this thickness direction, each convex portion 9 provided on one surface (the upper surface in FIG. 1B) of the lens main body portion 7 in the thickness direction, respectively. the position of the center of the position in the thickness direction of the other surface (see FIG. 1 (b) in the lower surface) to be that of each of the convex portions 11 provided around the lens unit 7 are consistent with each other (See FIG. 1 (a) etc.).

  The lens assembly 1 (main body portion 2) configured as described above includes, for example, a plurality of lens portions 3 including one convex portion 9 and one convex portion 11 facing the convex portion 9, and a peripheral portion 5. It is divided into. And each lens part 3 divided | segmented from the peripheral part 5 is used for the camera part of a mobile telephone, for example by providing image pick-up elements, such as CCD and a CMOS sensor, in this.

  The lens part 3 and the shape of the peripheral part 5 will be further described. One lens part 3 has a small circle indicating one arbitrary convex part 9 of the lens assembly 1 (main body part 2) shown in FIG. The locus obtained when moving in the direction perpendicular to the paper surface of FIG. 1A is a biconvex lens shape obtained by cutting the lens assembly 1 (main body portion 2).

  The peripheral portion 5 has a shape in which all the lens portions 3 are removed from the lens assembly 1 shown in FIG. 1A (a shape in which a large number of circular through holes are formed in the lens body portion 7). )

  In the above description, the outer periphery of the lens part 3 is made to coincide with the outer periphery of the convex part 9 or the convex part 11 (the outer diameter of the lens part 3, the outer diameter of the convex part 9, and the outer diameter of the convex part 11 are However, the outer diameter of the convex portion 9 may be different from the outer diameter of the convex portion 11, and the outer diameter of the lens portion 3 may be the outer diameter of the convex portion 9 or the outer diameter of the convex portion 11. And may be different.

  In FIG. 1A and the like, the number of the convex portions 9 and 11 is small. Actually, the outer diameter of the lens body 7 is about 6 inches to 8 inches, and hundreds to thousands of convex portions 9 and 11 are provided.

  In the lens assembly 1 shown in FIG. 1, the convex portions 9 and 11 are formed on the lens main body portion 7, but a plurality of spherical crown-shaped concave portions are provided on one surface in the thickness direction of the lens main body portion 7. The structure which provided the some convex part in the other surface of the thickness direction of the main-body part 7 may be sufficient, and the structure which provided the several recessed part in both surfaces of the thickness direction of the lens main-body part 7 may be sufficient. And the structure which provided the recessed part or the convex part only in one surface of the thickness direction of the lens main-body part 7 may be sufficient.

  And as the lens part 3, you may make it obtain not only a biconvex lens but a meniscus convex lens, a plano-convex lens, a meniscus concave lens, a biconcave lens, and a plano-concave lens.

  As the molding material constituting the main body 2, a resin such as a resin curable by irradiation with electromagnetic waves having a predetermined wavelength, a thermoplastic resin, a thermosetting resin, or a glass material can be used instead of the ultraviolet curable resin. However, here, an ultraviolet curable resin will be described as an example.

  The lens assembly 1 will be further described. The lens assembly 1 is provided with the release member 4 as described above. The release member 4 is provided integrally with the main body 2, and a part of the release member 4 protrudes from the main body 2.

  The release member 4 is provided in the peripheral part 5 of the main body part 2. Explaining in detail with examples, the release member 4 is made of a material such as resin or metal, and is formed in a rectangular thin flat plate shape. By being formed in a thin plate shape, the release member 4 is elastically deformed in the thickness direction and is easily bent (see FIG. 5).

  In addition, the release member 4 has a thickness direction that coincides with the thickness direction of the lens body portion 7, and a portion on one end side in the longitudinal direction is buried in the peripheral portion 5 of the body portion 2. A portion on the other end side in the longitudinal direction protrudes from the lens body 7 and is provided integrally with the lens body 7.

  Further, the release member 4 protrudes from the outer periphery of the main body so that the longitudinal direction thereof coincides with the radial direction of the circular main body 2 (lens main body 7).

  Further, a plurality of release members 4 are provided, for example, and these release members 4 are arranged at a predetermined interval on the peripheral portion 5 of the main body 2 (the outer periphery of the main body 2). . In the embodiment shown in FIG. 1, two release members 4 are provided at positions that divide the circular outer circumference of the main body 2 into two equal parts, but a plurality of release members 4 are provided in the main body. It may be provided at a position that equally divides the outer circumferential length of the circle 2 into three or more equal parts.

  Here, a manufacturing method of the lens assembly 1 will be described.

  First, as shown in FIG. 2, the uncured ultraviolet curable resin 13 is supplied to the lower mold M2 while the upper mold M1 is separated from the lower mold M2 (molding material supply process).

  Subsequently, the upper mold M1 is moved relative to the lower mold M2, and as shown in FIG. 3, the distance is increased until the distance between the upper mold M1 and the lower mold M2 becomes “L1”. When the distance between each other approaches “L1”, the shape of the space (ultraviolet curable resin 13) formed between the upper mold M1 and the lower mold M2 is the shape of the main body 2 of the lens assembly 1. It has a shape.

  Subsequently, the release member 4 is installed (release member installation step). In the state where the installation is completed, a part of the mold release member 4 enters the uncured ultraviolet curable resin 13 supplied in the molding material supply process. Further, the other part of the release member 4 protrudes from the uncured ultraviolet curable resin 13 supplied in the molding material supply process.

  It should be noted that the lens assembly 1 has a molding date (time if necessary), serial number, molding data (for example, type of molding material, intensity and irradiation time of ultraviolet rays, temperature, humidity, etc.), You may attach | subject at least one of identifiers, such as a barcode and QR code.

  Moreover, in order to prevent the release member 4 from moving (moving upward or downward in FIG. 3) due to gravity when the release member 4 is installed in the release member installation step, The release member 4 may be supported by the release member support 15. In this case, for example, it is desirable that the release member 4 is integrally supported by the release member support 15 by vacuum suction.

  Further, in FIG. 3, the release member 4 is disposed at the center of the ultraviolet curable resin 13 (lens assembly 1) (intermediate portion in the thickness direction of the lens body 7). The ultraviolet curable resin 13 may be cured while being attached to the upper mold M1 or the lower mold M2. In this case, the mold to which the release member 4 is attached is the mold on which the lens assembly 1 remains. For example, if the lens assembly 1 remains attached to the lower mold M2 when the upper mold M1 is separated from the lower mold M2, the release member 4 is attached to the lower mold M2.

  If the lens assembly 1 remains in either the upper mold M1 or the lower mold M2 when the upper mold M1 is separated from the lower mold M2, the mold release member 4 is provided on both the upper mold M1 and the lower mold M2. May be pasted.

  For example, in the state shown in FIG. 3, one release member 4 on the left side is made into two, and one of the two release members is more than the state shown in FIG. 3. Move downward to make contact with the lower mold M2, and move one of the two release members to the upper mold M1 by moving upward from the state shown in FIG. You may let them. Similarly, one release member 4 on the right side is made into two sheets, one release member is brought into contact with the lower mold M2, and the other release member is brought into contact with the upper mold M1. May be.

  Subsequently, after the release member 4 is installed in the release member installation process, the ultraviolet curable resin 13 is irradiated with ultraviolet rays and cured through the molds M1 and M2 (molding material curing process).

  Subsequently, as shown in FIG. 4, the upper mold M1 is moved to separate the upper mold M1 from the lower mold M2 (cured ultraviolet curable resin 13; lens assembly 1). When the upper mold M1 is separated from the lower mold M2, the lens assembly 1 is attached to the lower mold M2. For example, by changing the curvature radius of the convex portion 9 and the curvature radius of the convex portion 11 to each other, the cured ultraviolet curable resin 13 is strongly adhered to the lower mold M2 rather than the upper mold M1, and the lens assembly 1 is It is designed to stick to the lower mold M2.

  Subsequently, as shown in FIG. 5, after the ultraviolet curable resin 13 is cured in the molding material curing process, the protruding release member 4 is pulled upward to cure the cured ultraviolet curable resin 13 (lens assembly 1. ) Is released from the lower mold M2 (mold release process). Thereby, the lens assembly 1 can be obtained.

  By the way, in the lens assembly 1, a coupling force strengthening portion 17 for strengthening the coupling force with the main body portion 2 is provided at a portion (an embedded portion) engaged with the main body portion 2 of the release member 4. It may be formed (see FIGS. 6 to 10).

  6, 7, 8, and 10 increase the coupling force between the release member 4 and the main body 2 by changing the shape of the release member 4. What is shown by is strengthening the coupling | bonding force between the member 4 for mold release and the main-body part 2 by providing the coupling | bonding force reinforcement members, such as the pin 19. FIG.

  More specifically, the release member 4 (4A) of the lens assembly 1 shown in FIG. 6 is formed in an isosceles trapezoidal plate shape. And since the site | part of the wide bottom base side of 4 A of mold release members is embed | buried in the main-body part 2, the coupling | bonding force between the mold-release member 4 and the main-body part 2 is strengthened.

  The release member 4 (4B) of the lens assembly 1 shown in FIG. 7 is formed in a plate shape having a rectangular wide portion and a rectangular narrow portion. And since the part of the wide part is embed | buried in the main-body part 2, the coupling | bonding force between the member 4 for mold release and the main-body part 2 is strengthened.

  The release member 4 (4C) of the lens assembly 1 shown in FIG. 8 is formed in a rectangular plate shape, and is provided with a circular through hole 21 penetrating in the thickness direction. Then, the part of the release member 4C provided with the through hole 21 is buried in the main body 2 and the ultraviolet curable resin 13 enters the through hole 21, so that the release member 4 and the main body 2 The bond strength between is strengthened. A plurality of through holes 21 may be provided with a reduced size.

  The release member 4 (4D) of the lens assembly 1 shown in FIG. 9 is formed in a rectangular plate shape, and is provided with a through hole 21 penetrating in the thickness direction. Further, the pin 19 passes through the through hole 21. Thereby, the coupling | bonding force between the member 4 for mold release and the main-body part 2 is strengthened. The through hole 21 may be reduced in size and a plurality of the through holes 21 and the pins 19 may be provided.

  The release member 4 (4E) of the lens assembly 1 shown in FIG. 10 is formed in a rectangular plate shape, and a large number of small irregularities are provided in the portion buried in the main body 2. For example, the part buried in the main body 2 is bent in a wave shape such as a triangular wave shape. Thereby, the coupling | bonding force between the member 4 for mold release and the main-body part 2 is strengthened.

  When the molding material is a thermoplastic resin, the release member may be made of a thermoplastic resin. Accordingly, when the thermoplastic resin of the molding material and the release member are heated, the materials are softened or melted and mixed together, and the bonding force between the release member 4 and the main body 2 is increased. Strengthened. In this case, it is desirable that the release member is slightly harder to soften than the thermoplastic resin of the molding material.

  According to the lens assembly 1, the lens assembly 1 includes the release member 4, and by pulling the release member 4, the lens assembly 1 can be released (released) from the lower mold M <b> 2. Therefore, the lens assembly 1 can be easily released.

  That is, the lens assembly 1 can be released more efficiently than in the prior art, and it is not necessary to vacuum-suck the lens assembly 1 when releasing the lens assembly 1, thereby simplifying the configuration of the molding device for the lens assembly 1. be able to. Further, since no scraper or ejector pin is used, the risk of the lens assembly 1 being damaged can be avoided, and since compressed air is not flowed in, the environment can be kept clean.

  Further, according to the lens assembly 1, since the release member 4 is provided in the peripheral portion 5 of the lens assembly 1, the release member 4 does not get in the way and the release member 4 exists. It is possible to easily obtain the lens unit 3 that does not.

  Further, according to the lens assembly 1, since the coupling force strengthening portion 17 is formed, the coupling force between the main body portion 2 and the release member 4 is strong, and the lens assembly 1 is removed from the lower mold M2. When releasing, the lens assembly 1 can be pulled with a greater force.

  Further, according to the lens assembly 1, since the plurality of release members 4 are arranged at a predetermined interval around the peripheral portion 5 of the main body 2, the lens assembly 1 is released from the lower mold M <b> 2. Sometimes, the lens assembly 1 can be pulled with good balance. Then, the lens assembly 1 can be released in a state where an excessive force (including a moment or the like) is not applied to the lens assembly 1.

  In the above description, the lens assembly 1 having a plurality of lens portions 3 is described as an example. However, a lens assembly having only one lens portion 3 may be used as a molded product. Good. Moreover, you may employ | adopt things other than a lens as a molded article. For example, you may employ | adopt the thing provided with the moth eye structure as a principal part. Furthermore, you may use what is not divided into the principal part and a peripheral part as a molded article.

1 Lens assembly (molded product)
2 Body part 3 Lens part (main part)
4 Member for mold release 5 Peripheral part 17 Bonding strength strengthening part

Claims (1)

A molding material supply process for supplying uncured molding material to the lower mold;
The upper mold and the lower mold are placed so that a part of the uncured molding material supplied in the molding material supply step enters and the other part protrudes from the uncured molding material supplied in the molding material supply step. Between the molds, in a mode separated from the upper mold and the lower mold, or in a mode adhered to the upper mold or the lower mold, or both the upper mold and the lower mold In the attached mode, a release member installation step of installing a release member;
A molding material curing step for curing the molding material after installing the release member in the release member installation step;
After curing the molding material in the molding material curing step, by pulling the protruding release member, the mold release step of separating the cured molding material from the mold,
Molding method of a molded article, characterized in Rukoto to have a.

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