A mold, a mold master, and a method for manufacturing a mold

Abstract

The application discloses a mold, a mold master and a manufacturing method of the mold, relates to the technical field of Fresnel lenses, and aims to solve the problem that an existing mold cannot be used to manufacture a Fresnel lens with an oversized size. The mold comprises a first sub-mold and a second sub-mold. The first sub-mold comprises a first sub-mold main body and a plurality of first ring belt structures. The first sub-mold main body has a first structure surface, and the plurality of first ring belt structures are sequentially and nested arranged on the first structure surface. The second sub-mold comprises a second sub-mold main body and a plurality of second ring belt structures. The second sub-mold main body is connected with the first sub-mold main body and has a second structure surface. The second structure surface is mutually spliced with the first structure surface. The plurality of second ring belt structures are arranged on the second structure surface and sequentially and nested arranged on the periphery of the plurality of first ring belt structures. The plurality of first ring belt structures and the plurality of second ring belt structures are used to form Fresnel microstructures. The mold is used to process a Fresnel lens.

Description

Technical Field

[0001] This application relates to the field of Fresnel lens technology, and more particularly to a mold, a mold master, and a method for manufacturing the mold. Background Technology

[0002] Currently, to improve the projection effect of projection screens, projection screens generally include a Fresnel lens layer. The Fresnel lens layer enables the projected image to have higher brightness and contrast, resulting in a better projection effect. The Fresnel lens itself is mainly manufactured through mold transfer. Therefore, the processing quality of the mold has a significant impact on the structure of the Fresnel lens.

[0003] Currently, molds for making Fresnel lenses are generally manufactured using machine tools. However, due to the limitations of the machining dimensions of these machine tools, the molds produced cannot be used to produce ultra-large Fresnel lenses, thus failing to meet the market demand for ultra-large projection screens. Summary of the Invention

[0004] This application provides a mold, a mold master, and a method for manufacturing the mold, which solves the problem that existing molds cannot manufacture ultra-large Fresnel lenses.

[0005] To achieve the above objectives, this application adopts the following technical solution:

[0006] On one hand, embodiments of this application provide a mold, including a first sub-mold and a second sub-mold. The first sub-mold includes a first sub-mold body and a plurality of first annular structures. The first sub-mold body has a first structural surface, and the plurality of first annular structures are sequentially nested on the first structural surface. The second sub-mold includes a second sub-mold body and a plurality of second annular structures. The second sub-mold body is connected to the first sub-mold body and has a second structural surface. The second structural surface is spliced ​​with the first structural surface. The plurality of second annular structures are disposed on the second structural surface and sequentially nested around the plurality of first annular structures. The plurality of first annular structures and the plurality of second annular structures are used to form Fresnel microstructures.

[0007] The mold provided in this application embodiment is formed by splicing a first sub-mold and a second sub-mold. Thus, during mold manufacturing, the first and second sub-molds can be fabricated separately, then connected together, with the first structural surface of the first sub-mold and the second structural surface of the second sub-mold interlocked. Consequently, multiple sequentially nested first annular structures and multiple sequentially nested second annular structures surrounding the multiple first annular structures can be used to fabricate larger Fresnel microstructures. This allows the mold to be used to produce large-sized Fresnel lens layers, enabling the fabrication of large-sized projection screens and meeting market demand for ultra-large projection screens with Fresnel lens layers.

[0008] Meanwhile, since multiple second annular structures are nested around multiple first annular structures, meaning both the first and second annular structures are complete structures without any splicing between them, the seams of the mold have minimal impact on the Fresnel microstructure. This results in better fabrication of Fresnel lenses using this mold, ensuring the projection quality of the projection screen with the Fresnel lens.

[0009] In some embodiments, the mold is rectangular, and the first sub-mold body has a first splicing surface and a first arc surface that are interconnected. The second sub-mold body has a second splicing surface and a second arc surface that are interconnected; the first arc surface and the second arc surface are in contact with each other, and at least a portion of the first splicing surface is flush with at least a portion of the second splicing surface.

[0010] On the other hand, embodiments of this application provide a mold master having a Fresnel microstructure, which is formed by mold imprinting using any of the aforementioned molds.

[0011] Since the Fresnel microstructure of this mold master is formed by pressing with any of the aforementioned molds, this mold master can solve the same technical problems and achieve the same technical effects as the molds described above, which will not be elaborated further here.

[0012] On the other hand, an embodiment of this application provides a method for manufacturing a mold, comprising: fabricating a plurality of first annular structures nested sequentially on a first structural surface of a first sub-mold body to obtain a first sub-mold; fabricating a plurality of second annular structures nested sequentially on a second structural surface of a second sub-mold body to obtain a second sub-mold; and splicing the first sub-mold and the second sub-mold together to obtain a mold, such that the plurality of second annular structures are located around the plurality of first annular structures.

[0013] In some embodiments, forming a plurality of sequentially nested first annular structures on a first structural surface of a first sub-mold body includes: forming a first imprint layer on the first structural surface of the first sub-mold body; and imprinting the first imprint layer using a first conical roller mold to form a plurality of first annular structures.

[0014] In some embodiments, forming a plurality of sequentially nested second annular structures on the second structural surface of the second sub-mold body includes: forming a second imprint layer on the second structural surface of the second sub-mold body; and imprinting the second imprint layer using a second conical roller mold to form a plurality of second annular structures.

[0015] In some embodiments, splicing a first sub-mold and a second sub-mold together to obtain a mold includes: cutting the first sub-mold to obtain a first arc surface and a first splicing surface; cutting the second sub-mold to obtain a second arc surface and a second splicing surface; and splicing the first arc surface and the second arc surface together, making at least a portion of the first splicing surface and at least a portion of the second splicing surface flush.

[0016] In some embodiments, fabricating a plurality of sequentially nested first annular structures on a first structural surface of a first sub-mold body further includes: curing a first imprint layer. Fabricating a plurality of sequentially nested second annular structures on a second structural surface of a second sub-mold body further includes: curing a second imprint layer.

[0017] In some embodiments, fabricating a plurality of sequentially nested first annular structures on the first structural surface of the first sub-mold body further includes: adjusting the spacing between the first conical roller mold and the first structural surface according to the thickness of the first imprint layer. Fabricating a plurality of sequentially nested second annular structures on the second structural surface of the second sub-mold body further includes: adjusting the spacing between the second conical roller mold and the second structural surface according to the thickness of the second imprint layer.

[0018] In some embodiments, the first conical roller mold and the second conical roller mold are manufactured by CNC machining with a machining accuracy of ±1µm.

[0019] The technical effect of the above-described method for making molds is the same as that of the molds described above, and will not be repeated here. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram illustrating the usage state of the projection device provided in the embodiments of this application;

[0022] Figure 2 This is a schematic diagram of the Fresnel lens layer provided in an embodiment of this application;

[0023] Figure 3 for Figure 2 The cross-sectional view of the Fresnel lens layer is shown below;

[0024] Figure 4 A schematic diagram of the structure of a mold provided in an embodiment of this application;

[0025] Figure 5 for Figure 4 The cross-sectional view of the mold shown;

[0026] Figure 6 for Figure 4 The diagram shows the overall structure of the first sub-mold.

[0027] Figure 7 for Figure 4 The diagram shows the overall structure of the second sub-mold.

[0028] Figure 8 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 1 ;

[0029] Figure 9 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 2 ;

[0030] Figure 10 This is a structural diagram of the first sub-mold made using the first conical roller mold;

[0031] Figure 11 This is a schematic diagram of the structure of a first conical roller mold provided in an embodiment of this application;

[0032] Figure 12 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 3 ;

[0033] Figure 13 This is a structural diagram of the second sub-mold made using the second conical roller mold;

[0034] Figure 14 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 4 ;

[0035] Figure 15 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 5 ;

[0036] Figure 16 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 6 ;

[0037] Figure 17 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 7 ;

[0038] Figure 18 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 8 .

[0039] Figure label:

[0040] 100-Projection device; 1-Projection screen; 11-Surface layer; 12-Coloring layer; 13-Diffusion layer; 131-Diffusion particles; 14-Fresnel lens layer; 15-Reflective layer; 2-Projector; 21-Incident light; 22-Outgoing light; 3-Audience; 4-Ambient light source; 200-Mold; 51-First sub-mold; 511-First sub-mold body; 5111-First structural surface; 5112-First splicing surface; 5113-First arc surface; 512-First ring structure; 513-First embossing layer; 52-Second sub-mold; 521-Second sub-mold body; 5211-Second structural surface; 5212-Second splicing surface; 5213-Second arc surface; 5214-Second sub-splicing surface; 522-Second ring structure; 300-First conical roller mold; 301-Microstructure; 400-Second conical roller mold. Detailed Implementation

[0041] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0042] In the description of this application, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", "inner", "outer", "center", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0043] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined as "first" or "second" may be used to explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0044] It should be noted that in practical applications, due to limitations in equipment precision or installation errors, achieving absolute parallelism or perpendicularity is difficult. The descriptions of perpendicularity, parallelism, or unidirectional orientation in this application are not absolute limitations, but rather indicate that perpendicular or parallel structural settings can be achieved within a preset error range, thus maximizing the technical effect of the defined features and making the corresponding technical solution easy to implement, exhibiting high feasibility.

[0045] In embodiments of this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0046] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0047] In the field of projection display technology, especially in the field of ultra-short-throw laser projection display, in order to achieve better brightness and display effect, projectors can be used with projection screens with Fresnel microstructures, thereby giving the projection screens a certain degree of resistance to ambient light and improving the user's viewing experience.

[0048] like Figure 1 As shown, Figure 1 This is a schematic diagram illustrating the usage state of the projection device 100 provided in this application embodiment. The projection device 100 may include a projection screen 1 and a projector 2. When in use, the projector 2 can be placed in front of and below the projection screen 1, and the viewer 3 is positioned in front of the projection screen 1 and looking at it. The incident light 21 emitted by the projector 2 shines onto the projection screen 1, and after being reflected by the projection screen 1, the incident light 21 finally forms an outgoing light 22 that shines onto the viewer 3, while simultaneously forming an image on the projection screen 1.

[0049] Projector 2 may include a laser, which can be one of a monochromatic laser, a dual-color laser, or a tri-color laser. The tri-color laser can emit blue, red, and green laser light. The wavelength range of the emitted blue laser can be set to 430nm-460nm, the wavelength range of the emitted green laser can be set to 500nm-540nm, and the wavelength range of the emitted red laser can be set to 610nm-650nm.

[0050] Because tri-color lasers have the advantages of accurate color reproduction and a wide color gamut, the laser in the projector 2 provided in this embodiment can be a tri-color laser. Of course, the laser in the projector 2 provided in this embodiment can also be a monochromatic laser or a dual-color laser.

[0051] Continue to refer to Figure 1 The projection screen 1 may include a surface layer 11, a coloring layer 12, a diffusion layer 13, a Fresnel lens layer 14, and a reflective layer 15 stacked together.

[0052] The surface layer 11 can be used to protect the projection screen 1, making it less susceptible to damage. The surface layer 11 can be made of a rigid material to form a rigid protective layer. For example, the surface layer 11 can be made of methyl methacrylate-styrene copolymer (MS).

[0053] The coloring layer 12 contains dark dyes, which can be used to improve the contrast of the projection screen 1. Because the coloring layer 12 contains dark dyes, ambient light entering the projection screen 1 passes through the coloring layer 12 and is absorbed by the dark dyes, thus resulting in a higher contrast of the projection screen 1. The dark dyes can be organic pigments, such as azo dyes or phthalocyanine dyes.

[0054] The diffusion layer 13 contains diffusion particles 131, which can be used to diffuse the light entering the projection screen 1, thereby expanding the viewing angle of the projection screen 1.

[0055] After the light projected by the projector 2 enters the interior of the projection screen 1, it passes through the diffusion particles 131 in the diffusion layer 13. At this time, the light is diffused under the action of the diffusion particles 131, thereby increasing the viewing angle of the projection screen 1.

[0056] Meanwhile, due to the diffusion of light, the coherence between the diffused light rays decreases, thereby reducing the severity of speckle on the surface of the projection screen 1. The material of the diffusion particles 131 can be polymethyl methacrylate (PMMA).

[0057] The reflective layer 15 is used to reflect light, allowing it to re-emit from the surface layer 11. It is understood that a reflective material is distributed within the reflective layer 15 to enable light reflection. For example, the reflective material may be aluminum, silver, or a combination of aluminum and silver.

[0058] like Figure 1 As shown, the projection screen 1 includes a Fresnel lens layer 14, which can converge light to the center of the projection screen 1, so that the audience 3 can see a brighter image when facing the projection screen 1.

[0059] In addition, the ambient light 41 emitted by the ambient light source 4 is reflected to the area not viewed by the human eye when it passes through the Fresnel lens layer 14, reducing the interference of the ambient light 41 and making the viewing experience of the audience 3 better.

[0060] It is understandable that, such as Figure 2 As shown, Figure 2 This is a schematic diagram of the structure of a Fresnel lens layer 14 provided in an embodiment of this application. The Fresnel lens layer 14 is composed of multiple concentric annular prisms located on the same plane. Figure 3 As shown, Figure 3 for Figure 2 The cross-sectional view of the Fresnel lens layer 14 shown is shown. The cross-sectional shape of the Fresnel lens layer 14 can be serrated.

[0061] Because projection screens with Fresnel lens layers 14 provide better projection effects, such projection screens 1 have gradually become the mainstream choice for users. As an important component of the projection screen 1, the Fresnel lens layer 14 is typically manufactured using a dedicated mold for hot pressing transfer or UV photolithography curing transfer. The processing quality of the mold has a significant impact on the final effect of the Fresnel lens layer 14.

[0062] In related technologies, Fresnel molds can be fabricated using high-precision diamond machining tools to create flat Fresnel molds, which can then be used to imprint Fresnel lens layers. However, the above method of mold fabrication is easily limited by the machining size of the machine tool, with a maximum machining diameter of no more than 3.4m, which can only meet the production needs of Fresnel molds of 100 inches and below.

[0063] like Figure 2 As shown, Fresnel lenses are composed of multiple concentric ring prisms. Correspondingly, during mold manufacturing, the machining tools generally require rotary processing. For Fresnel lens layers of 100 inches and above, refer to... Figure 2 When making the mold, the machining radius R of the machine tool must be at least greater than 1.6m.

[0064] Currently, there are few machines capable of processing molds for producing Fresnel lens layers larger than 100 inches, and the processing cost is high. Furthermore, as the size of the machine tools increases, the machining accuracy and stability of the structure decrease accordingly. Since the design dimensions of Fresnel structures are typically in the hundreds of micrometers, the resulting structures have poor performance.

[0065] Based on this, embodiments of this application provide a mold, such as Figure 4 As shown, Figure 4 This is a schematic diagram of the structure of a mold 200 provided in an embodiment of this application. The mold 200 includes a first sub-mold 51 and a second sub-mold 52.

[0066] like Figure 5 As shown, Figure 5 for Figure 4 The cross-sectional view of mold 200 shown indicates that the first sub-mold 51 includes a first sub-mold body 511 and multiple first annular structures 512. The first sub-mold body 511 has a first structural surface 5111, and the multiple first annular structures 512 are sequentially nested on the first structural surface 5111, i.e., as shown... Figure 3 As shown, multiple first ring structures 512 are located sequentially around adjacent first ring structures 512.

[0067] Continue to refer to Figure 5 The second sub-mold 52 includes a second sub-mold body 521 and multiple second ring structures 522. The second sub-mold body 521 is connected to the first sub-mold body 511. The second sub-mold 52 has a second structural surface 5211, which is spliced ​​with the first structural surface 5111, that is, the first structural surface 5111 and the second structural surface 5211 are spliced ​​to form a larger plane.

[0068] Multiple second ring structures 522 are nested on the second structural surface 5211, and as shown... Figure 4 As shown, multiple second annular structures 522 are nested sequentially around multiple first annular structures 512. The multiple first annular structures 512 and the multiple second annular structures 522 can be used to form Fresnel microstructures.

[0069] Therefore, the mold 200 provided in this embodiment is formed by splicing a first sub-mold 51 and a second sub-mold 52. In this way, when manufacturing the mold 200, the first sub-mold 51 and the second sub-mold 52 can be manufactured separately, then connected together, with the first structural surface 5111 of the first sub-mold 51 and the second structural surface 5211 of the second sub-mold 52 spliced ​​together. Thus, a plurality of sequentially nested first annular structures 512 and a plurality of sequentially nested second annular structures 522 surrounding the plurality of first annular structures 512 can be used to manufacture larger-sized Fresnel microstructures, thereby enabling the mold 200 to be used to produce large-sized Fresnel lens layers, realizing the manufacture of large-sized projection screens and meeting the market demand for ultra-large-sized projection screens with Fresnel lens layers.

[0070] Meanwhile, since multiple second annular structures 522 are nested around multiple first annular structures 512, meaning that both the first and second annular structures 512 are complete structures without any splicing between them, the seams of the mold have minimal impact on the Fresnel microstructure. This results in a better fabrication effect for the Fresnel lens produced using the mold 200, ensuring the projection effect of the projection screen with the Fresnel lens.

[0071] As described above, Fresnel microstructures consist of multiple concentric ring-shaped prisms located on the same plane. Therefore, it can be understood that, as... Figure 5 As shown, the first annular structure 512 and the second annular structure 522 can be prismatic lens structures with a triangular cross-section. The included angle θ formed by the prismatic lens structures can be set according to actual needs. For example, θ can be 5° to 85°.

[0072] At the same time, such as Figure 4 As shown, the multiple first ring structures 512 and the multiple second ring structures 522 are all arc-shaped, and the center of the multiple first ring structures 512 and the center of the multiple second ring structures 522 can coincide.

[0073] Furthermore, it is understandable that, referring to Figure 4 , Figure 4 The dashed line indicates the splicing position of the first sub-mold 51 and the second sub-mold 52. To ensure that the mold 200 formed by splicing the first sub-mold 51 and the second sub-mold 52 can manufacture well-structured Fresnel microstructures, a first annular structure 512 is also provided at the splicing position indicated by the dashed line. Thus, after the first sub-mold 51 and the second sub-mold 52 are spliced, multiple first annular structures 512 and multiple second annular structures 522 can imprint complete Fresnel microstructures.

[0074] like Figure 4As shown, in some embodiments, the mold 200 can be rectangular. Since the mold 200 is rectangular, when using the mold 200 to produce Fresnel lenses, a rectangular Fresnel lens can be directly imprinted on a rectangular plane of the corresponding size.

[0075] Since projection screens are generally rectangular, the Fresnel lens layer can be directly fabricated on... Figure 2 The surface of the diffusion layer 13 shown is used to make a Fresnel lens layer 14 using the mold 200. The Fresnel lens layer 14 made by the mold 200 can be used without further cutting, which improves the production efficiency of the projection screen 1.

[0076] When the mold 200 is rectangular, such as Figure 6 As shown, Figure 6 for Figure 4 The schematic diagram of the overall structure of the first sub-mold 51 shown indicates that the main body 511 of the first sub-mold has a first splicing surface 5112 and a first arc surface 5113 that are interconnected. Figure 7 As shown, Figure 7 for Figure 4 The schematic diagram of the overall structure of the second sub-mold 52 shown shows that the main body 521 of the second sub-mold has a second splicing surface 5212 and a second arc surface 5213 that are connected to each other.

[0077] When the first sub-mold 51 and the second sub-mold 52 are joined together, the first arc surface 5113 and the second arc surface 5213 fit together, and at least a portion of the first joining surface 5112 is flush with at least a portion of the second joining surface 5212, that is, as shown in the figure. Figure 4 As shown, the first sub-mold 51 and the second sub-mold 52 are spliced ​​together to form a rectangular mold 200.

[0078] It can be understood that the center of the first arc surface 5113 coincides with the center of the first ring structure 512, and the center of the second arc surface 5213 coincides with the center of the second ring structure 522.

[0079] Furthermore, it is understandable that Figure 6 The first sub-mold 51 shown is a three-dimensional structure with a certain thickness. Multiple first annular structures 512 are disposed on one side of the surface of the first sub-mold body 511. The first arc surface 5113 and the first splicing surface 5112 are the surfaces of the first sub-mold body 511 located on the sides of the multiple first annular structures 512. Similarly, Figure 7 The second arc surface 5213 and the second splicing surface 5212 shown are the surfaces located on the sides of the multiple second ring structures 522 in the second sub-mold body 521.

[0080] For example, such as Figure 6As shown, the first arc surface 5113 can be semi-circular. Correspondingly, as... Figure 7 As shown, the second splicing surface 5212 includes two second sub-splicing surfaces 5214, and the second arc surface 5213 connects the two second sub-splicing surfaces 5214. That is, as... Figure 7 As shown, the second sub-mold 52 can be a rectangular shape with a notch on one side, and the notch is the second arc surface 5213. In this way, the arc of the first sub-mold 51 can be inserted into the notch of the second sub-mold 52 to form a rectangular mold.

[0081] The center of the circle corresponding to the second arc surface 5213 can be located on the central axis of the second sub-mold 52. Thus, as... Figure 4 As shown, the centers of the multiple first ring structures 512 and second ring structures 522 of the mold 200 formed after splicing are also located on the central axis of the mold 200.

[0082] To reduce wear and tear on the mold 200, this application embodiment also provides a mold master plate, which has a Fresnel microstructure formed by the mold imprinting process described above. Thus, when manufacturing the Fresnel lens layer, the mold master plate can be used, thereby reducing the number of times the mold is used, decreasing mold wear, and extending the mold's service life. It should be understood that the mold master plate is a complete mold master plate.

[0083] Meanwhile, since the mold master is formed by the above-mentioned mold imprinting, the Fresnel microstructure of the mold master is relatively large, which can be used to imprint large-size Fresnel lens layers to meet the market demand for large-size projection screens.

[0084] In some embodiments, the mold master can be made of a flexible material. Because of its flexibility, the mold master can be fixed to the cylindrical surface of a cylindrical roller. Therefore, when manufacturing Fresnel lens layers, the cylindrical roller can be rotated to continuously process and produce Fresnel lens layers, improving production efficiency. It is understood that the material of the mold master can be selected according to actual conditions, and no further limitations are made here.

[0085] Of course, the mold master can also be made of a non-rollable material. In this case, when making the Fresnel lens layer, the Fresnel lens layer can be directly imprinted onto the surface of the mold master with the Fresnel microstructure.

[0086] This application also provides a method for manufacturing a mold, such as... Figure 8 As shown, Figure 8 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 1 The method includes steps S100 to S300.

[0087] S100: Multiple first ring structures nested sequentially are made on the first structural surface of the first sub-mold body to obtain the first sub-mold.

[0088] S200: Multiple second ring structures nested in sequence are made on the second structural surface of the second sub-mold body to obtain the second sub-mold.

[0089] S300: The first sub-mold and the second sub-mold are spliced ​​together to obtain a mold, so that multiple second ring structures are located on the periphery of multiple first ring structures.

[0090] For example, when making the first sub-mold and the second sub-mold, the main body of the first sub-mold and the main body of the second sub-mold can be placed on a glass platform for production.

[0091] It is understandable that the aforementioned first sub-mold body and second sub-mold body are... Figure 5 The first sub-mold body 511 and the second sub-mold body 521 of the mold 200 provided in the embodiment of this application are shown.

[0092] The materials of the first sub-mold body 511 and the second sub-mold body 521 can be selected according to actual conditions. The first sub-mold body 511 and the second sub-mold body 521 can be made of the same material. For example, the first sub-mold body 511 and the second sub-mold body 521 can be made of glass, PMMA, polycarbonate (PC), polyethylene terephthalate (PET), or other transparent materials. As an example, the first sub-mold body 511 and the second sub-mold body 521 can be made of PET material. PET material has a decomposition temperature of approximately 353°C, which is relatively high and ensures that the structure is not damaged during processing.

[0093] Furthermore, the thickness of the first sub-mold body 511 and the second sub-mold body 521 can be selected according to actual conditions. For example, the first sub-mold body 511 and the second sub-mold body 521 can be made of PET material with a thickness of 0.3mm to 0.8mm.

[0094] The mold produced using the above method can be used to manufacture ultra-large Fresnel lenses, meeting market demand for ultra-large projection screens. Furthermore, since the multiple second annular structures are located around the multiple first annular structures, there are no splicing marks between the first and second annular structures. The impact of the splicing points on the Fresnel structure is minimized, ensuring the manufacturing quality of the Fresnel lenses produced using this mold, thereby improving the projection effect of the projection screen including the Fresnel lens.

[0095] Furthermore, it is understood that the order of steps S100 and S200 can be reversed. For example, step S100 can be executed first, followed by step S200. Alternatively, step S200 can be executed first, followed by step S100.

[0096] In some embodiments, such as Figure 9 As shown, Figure 9 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 2 The process of creating multiple nested first ring structures on the first structural surface of the first sub-mold body includes steps S101-102.

[0097] S101: Create the first imprint layer on the first structural surface of the first sub-mold body.

[0098] For example, the first embossing layer can be made of resin adhesive. For instance, the first embossing layer can be made of thermosetting adhesive or UV-curing adhesive. When making the first embossing layer, thermosetting adhesive or UV adhesive can be applied to the first structural surface. Embossing is easier when the first embossing layer is made using the above materials.

[0099] S102: Use a first conical roller mold to imprint a first imprint layer to form a plurality of first annular structures.

[0100] For example, such as Figure 10 As shown, Figure 10 This is a schematic diagram of the structure when the first conical roller mold 300 is used to make the first sub-mold 51. The first sub-mold 51 can be made by rotating the first conical roller mold 300 around one end as an axis and pressing the first imprint layer 513.

[0101] It is understandable that, such as Figure 11 As shown, Figure 11 This is a schematic diagram of the structure of a first conical roller mold 300 provided in an embodiment of this application. The conical surface of the first conical roller mold 300 is provided with microstructures 301 for imprinting a first annular structure. Figure 10 After rotating as shown, the first imprint layer 513 can be obtained. Figure 4 The first ring structure 512 is shown as having multiple nested configurations.

[0102] As can be seen from the above, the first sub-mold 51 is relatively small in size. Therefore, in some other embodiments, the first sub-mold 51 can also be directly manufactured by a mold-making machine tool.

[0103] In some embodiments, such as Figure 12 As shown, Figure 12 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 3The process of creating multiple nested second ring structures on the second structural surface of the second sub-mold body includes steps S201 to S202.

[0104] S201: Create a second embossing layer on the second structural surface of the second sub-mold body.

[0105] S202: Use a second conical roller mold to imprint a second imprint layer to form multiple second annular structures.

[0106] Similarly, such as Figure 13 As shown, Figure 13 This is a schematic diagram illustrating the structure of the second sub-mold 52 when using the second conical roller mold 400 to create the second sub-mold 52. The second sub-mold 52 is obtained by rotating the second conical roller mold 400 around one end as an axis and pressing in the second imprint layer 523. It can also be understood that the structure of the second conical roller mold 400 is similar to... Figure 11 The structure of the first conical roller mold 300 shown is similar, except that the size of the second conical roller mold 400 is larger than that of the first conical roller mold 300.

[0107] In some embodiments, such as Figure 14 As shown, Figure 14 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 4 The process of splicing the first sub-mold and the second sub-mold together to obtain the mold includes steps S301 to S303.

[0108] S301: Cut the first sub-mold to obtain the first arc surface and the first splicing surface.

[0109] For example, such as Figure 10 As shown, after being pressed by the first conical roller mold 300, a first annular sub-mold 51 can be formed. At this time, it can be moved along... Figure 10 The first sub-mold 51 is cut along the dotted lines shown, resulting in... Figure 6 The first sub-mold 51 is shown.

[0110] S302: Cut the second sub-mold to obtain the second arc surface and the second splicing surface.

[0111] Similarly, such as Figure 13 As shown, after being pressed by the second conical roller mold 400, a second annular sub-mold 52 can be formed. At this time, it can be along... Figure 13 The second sub-mold 52 is cut along the dotted lines shown, resulting in... Figure 7 The second sub-mold 52 is shown.

[0112] S303: Join the first arc surface and the second arc surface together, and make the first joining surface and the second joining surface flush.

[0113] In obtaining Figure 6 The first sub-mold 51 shown and Figure 7 After the second sub-mold 52 shown, the first arc surface 5113 and the second arc surface 5213 can be spliced ​​together, and the first splicing surface 5112 and the second splicing surface 5212 can be made flush, to obtain Figure 4 The mold 200 shown. The first arc surface 5113 and the second arc surface 5213 can be joined together by adhesive bonding.

[0114] In some embodiments, such as Figure 15 As shown, Figure 15 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 5 The process of creating multiple nested first ring structures on the first structural surface of the first sub-mold body also includes step S103.

[0115] S103: Curing the first imprint layer.

[0116] As described above, the first imprinted layer can be made of resin adhesive, such as thermosetting adhesive or UV-curing adhesive. This allows the material to be cured during the fabrication of the first annular structure, enabling the first imprinted layer to better form the first annular structure.

[0117] The curing process of the first imprinted layer can be completed at different times. For example, the first imprinted layer can be cured during the fabrication of multiple nested first annular structures using the first conical mold. Alternatively, the first imprinted layer can be cured after the first conical mold has been used for imprinting.

[0118] like Figure 16 As shown, Figure 16 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 6 The process of creating multiple nested second ring structures on the second structural surface of the second sub-mold body also includes step S203.

[0119] S203: Curing the second imprint layer.

[0120] The second imprinted layer can also be made of resin adhesive, such as thermosetting adhesive or UV-curing adhesive. This allows the second imprinted layer to be cured during the fabrication of the second annular structure, enabling it to better form the second annular structure.

[0121] Similarly, the curing process of the second imprinted layer can be completed at different times. For example, the second imprinted layer can be cured during the fabrication of multiple nested second annular structures using the second conical mold. Alternatively, the second imprinted layer can be cured after the imprinting process using the second conical mold is completed.

[0122] It is understandable that since the first and second imprinting layers are made of different materials, their curing methods will also differ. For example, when the first and second imprinting layers are made of thermosetting adhesive, a thermosetting system can be used to cure them. When the first and second imprinting layers are made of UV-curable adhesive, a UV light source can be used to cure them.

[0123] In some embodiments, such as Figure 17 As shown, Figure 17 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 7 The process of creating multiple nested first ring structures on the first structural surface of the first sub-mold body also includes step S104.

[0124] S104: Adjust the distance between the first conical roller mold and the first structural surface according to the thickness of the first imprint layer.

[0125] like Figure 18 As shown, Figure 18 A schematic flowchart of a mold manufacturing method provided in this application embodiment. Figure 8 The process of creating multiple nested second ring structures on the second structural surface of the second sub-mold body also includes step S204.

[0126] S204: Adjust the distance between the second conical roller mold and the second structural surface according to the thickness of the second imprint layer.

[0127] It is understandable that, in order to avoid damage to the first and second structural surfaces during processing, the first and second conical roller molds can have a certain gap with the first and second structural surfaces. Of course, the gap between the first conical roller mold and the first structural surface should be less than the thickness of the first imprint layer, and the gap between the second conical roller mold and the second structural surface should be less than the thickness of the second imprint layer.

[0128] In some embodiments, the first conical roller mold and the second conical roller mold can be manufactured by CNC machining with a machining accuracy of ±1µm. The first conical roller mold and the second conical roller mold manufactured in the above manner have good structural accuracy.

[0129] Correspondingly, the first ring structure imprinted by the first conical roller mold and the second ring structure imprinted by the second conical roller mold have high structural precision and good mold manufacturing effect. The Fresnel lens layer made by this mold has good structural precision, and the texture of the projected image will be greatly improved.

[0130] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of protection described in the claims.

Claims

1. A mold, characterized in that, include: The first sub-mold includes a first sub-mold body and multiple first annular structures; the first sub-mold body has a first structural surface; the multiple first annular structures are sequentially nested on the first structural surface; and... The second sub-mold includes a second sub-mold body and multiple second ring structures; the second sub-mold body is connected to the first sub-mold body; the second sub-mold body has a second structural surface; the second structural surface and the first structural surface are spliced ​​together; the multiple second ring structures are disposed on the second structural surface and are sequentially nested around the multiple first ring structures; The plurality of first annular structures and the plurality of second annular structures are used to form Fresnel microstructures.

2. The mold according to claim 1, characterized in that, The mold is rectangular; the first sub-mold body has a first splicing surface and a first arc surface that are connected to each other; the second sub-mold body has a second splicing surface and a second arc surface that are connected to each other; the first arc surface and the second arc surface are in contact with each other, and at least a portion of the first splicing surface is flush with at least a portion of the second splicing surface.

3. A mold master plate, characterized in that, The mold master has a Fresnel microstructure; the Fresnel microstructure is formed by mold imprinting as described in claim 1 or 2.

4. A method for manufacturing a mold, characterized in that, include: Multiple nested first ring structures are fabricated on the first structural surface of the first sub-mold body to obtain the first sub-mold; Multiple nested second ring structures are fabricated on the second structural surface of the second sub-mold body to obtain the second sub-mold; The mold is obtained by splicing the first sub-mold and the second sub-mold together, so that multiple second ring structures are located on the periphery of multiple first ring structures.

5. The method for manufacturing a mold according to claim 4, characterized in that, The process of fabricating multiple nested first annular structures on the first structural surface of the first sub-mold body includes: A first imprint layer is formed on the first structural surface of the first sub-mold body; The first imprinted layer is pressed using a first conical roller die to form a plurality of the first annular structures.

6. The method for manufacturing a mold according to claim 5, characterized in that, The process of fabricating multiple nested second annular structures on the second structural surface of the second sub-mold body includes: A second embossing layer is formed on the second structural surface of the second sub-mold body; The second imprint layer is pressed using a second conical roller die to form a plurality of the second annular structures.

7. The method for manufacturing a mold according to claim 6, characterized in that, The step of splicing the first sub-mold and the second sub-mold together to obtain the mold includes: Cut the first sub-mold to obtain the first arc surface and the first splicing surface; Cut the second sub-mold to obtain the second arc surface and the second splicing surface; The first arc surface is joined with the second arc surface, and at least a portion of the first joining surface and at least a portion of the second joining surface are made flush.

8. The method for manufacturing a mold according to claim 6, characterized in that, The step of fabricating multiple nested first annular structures on the first structural surface of the first sub-mold body further includes: The first imprinted layer is cured; The method of fabricating multiple nested second annular structures on the second structural surface of the second sub-mold body further includes: The second imprinted layer is cured.

9. The method for manufacturing a mold according to claim 6, characterized in that, The step of fabricating multiple nested first annular structures on the first structural surface of the first sub-mold body further includes: Adjust the distance between the first conical roller mold and the first structural surface according to the thickness of the first imprinted layer; The method of fabricating multiple nested second annular structures on the second structural surface of the second sub-mold body further includes: Adjust the distance between the second conical roller mold and the second structural surface according to the thickness of the second imprint layer.

10. The method for manufacturing a mold according to claim 6, characterized in that, The first conical roller mold and the second conical roller mold are manufactured by CNC machining with a machining accuracy of ±1µm.

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