Optical module molding system and optical module molding method

Abstract

The present application relates to the field of optics, and provides an optical module forming system, which comprises a pre-forming seat body, an alignment module, a mold cover body and an injection pump. The pre-forming seat body is used for carrying an optical product, and the pre-forming seat body comprises a light transmission channel penetrating through the pre-forming seat body. The alignment module is used for confirming the feeding angle of the optical product. The mold cover body is used for combining with the pre-forming seat body to form an injection forming mold. The injection pump is used for injecting a lens material in a molten state into the injection forming mold. The present application also provides an optical module forming method, which is a method for forming an optical module by using the aforementioned optical module forming system. The present application can save the use of optical glue, and achieve the effects of simplifying the process and improving the product yield.

Description

Technical Field

[0001] This application relates to the field of optics, and in particular to an optical module forming system and an optical module forming method. Background Technology

[0002] In the current manufacturing process of optical modules, lenses and optical films are stacked in a specific order, and are usually bonded together with optical adhesive. Pressure is then used to bond the lenses and optical films together. Generally, optical module bonding methods are divided into contact and non-contact methods. Contact bonding uses a contoured pressure head to apply pressure directly, while non-contact bonding uses positive pressure gas to provide pressure.

[0003] However, current optical modules typically include multiple lenses, various optical films, and optical adhesives. Therefore, multiple bonding processes are required to assemble the optical module, along with other additional bonding processes. This makes the current optical module manufacturing process complex, requiring multiple high-temperature and high-pressure bonding processes. Furthermore, the optical adhesive needs to be cured by heating or irradiation with ultraviolet light. In addition, a high-temperature and high-pressure degassing step is required to remove residual gas between the lenses and optical films or residual gas in the optical adhesive. This is to prevent the formation of air bubbles during the optical module manufacturing process, which could lead to conditions such as optical film deformation, affecting the optical imaging quality of the optical module and the product yield.

[0004] In addition, using optical adhesives in optical module bonding has other disadvantages. During the curing process, adhesive residue may fall off or remain, increasing the risk of contamination between the layers of the optical module. Furthermore, the fabrication of optical modules involves multiple loading and unloading processes, requiring repeated alignment of lenses and optical films, increasing the risk of misalignment. Moreover, the bonding process requires a large amount of optical adhesive and corresponding release film, meaning the cost of the optical module fabrication includes the cost of the aforementioned materials. Additionally, the use of multiple high-temperature, high-pressure processes to bond the layers of the optical module adds extra energy costs. Summary of the Invention

[0005] One objective of this application is to address the problems in the related technologies of using optical adhesive to bond optical modules, which result in complex manufacturing processes, risks of optical module defects, and high bonding costs.

[0006] Based on the purpose of this application, this application provides an optical module molding system, including a preform base, an alignment module, a mold cover, and an injection pump; the preform base includes a light-transmitting channel that extends through the preform base, and the preform base is used to support optical products; the alignment module includes a light emitter and a light detector, the light emitter is used to emit alignment light into the light-transmitting channel, and the light detector is used to detect the alignment light; the mold cover is used to combine with the preform base to form an injection molding mold, the injection molding mold includes an injection hole and a mold cavity, and the injection hole and the mold cavity are interconnected; the injection pump is used to inject molten lens material into the mold cavity of the injection molding mold through the injection hole.

[0007] In one embodiment of this application, the material of the light-transmitting channel is a light-transmitting material.

[0008] In one embodiment of this application, the light transmission channel also includes a condenser lens.

[0009] In one embodiment of this application, the light-transmitting channel also includes an optical fiber.

[0010] In one embodiment of this application, the preformed base includes a movable stage and a contouring part. The contouring part is disposed on the movable stage and is used to support optical products. A light-transmitting channel passes through the movable stage and the contouring part.

[0011] In one embodiment of this application, the materials of the movable stage, the contouring part, and the light-transmitting channel are all light-transmitting materials.

[0012] In one embodiment of this application, the surface of the preformed base facing the optical product and the surface of the light-transmitting channel facing the optical product further include a light-transmitting hard coating.

[0013] In one embodiment of this application, the injection pump includes a material tank, a syringe, and a heating module. The syringe is connected to the material tank, and the heating module is disposed on the outside of the syringe. The material tank contains lens material and is used to supply the lens material to the syringe. The heating module provides heat energy to the syringe, causing the lens material in the syringe to melt into a molten state.

[0014] Based on the purpose of this application, this application also provides an optical module molding method, comprising the following steps: providing an optical module molding system as described above; placing an optical product on a pre-molding base at a position corresponding to the light-transmitting channel; an alignment module confirming whether the loading angle of the optical product on the pre-molding base is correct; if it is correct, proceeding to the next step; if it is incorrect, returning to the previous step; pre-molding the optical product on the pre-molding base into a pre-molded optical product; assembling the pre-molding base and the mold cover into an injection molding mold, with the pre-molded optical product located in the mold cavity of the injection molding mold; injecting molten lens material through an injection hole into the mold cavity of the injection molding mold using an injection pump; solidifying the molten lens material in the mold cavity of the injection molding mold to form a lens that adheres to the pre-molded optical product, the pre-molded optical product and the lens together forming an optical module; and separating the pre-molding base, the mold cover, and the optical module from each other.

[0015] In one embodiment of this application, the molten lens material is formed by heating and melting the lens material using an injection pump.

[0016] In summary, this application not only simplifies the manufacturing process of optical modules by eliminating the use of optical adhesive, but also simplifies the stacking structure of optical modules, allowing for a further reduction in the thickness of the optical modules. It also reduces the risk of product defects caused by air bubbles during the bonding process using optical adhesive. Therefore, this application is beneficial for improving the production yield of optical modules. Attached Figure Description

[0017] Figure 1 This is a top view of the preformed base.

[0018] Figure 2 This is a schematic diagram showing how the alignment light passes through the light transmission channel and then penetrates the optical product.

[0019] Figure 3 This is a schematic diagram of an optical product being pre-formed into a pre-formed optical product on a pre-forming base.

[0020] Figure 4 This is a schematic diagram of an injection pump injecting lens material into the cavity of an injection molding mold.

[0021] Figure 5 This is a step diagram of the optical module forming method.

[0022] Explanation of reference numerals in the attached figures:

[0023] 1: Pre-formed base body;

[0024] 2: Alignment module;

[0025] 3: Mold cover;

[0026] 10: Mobile platform;

[0027] 12: Copying department;

[0028] 20: Light emitter;

[0029] 22: Light detector;

[0030] 24: Polarizer;

[0031] 40: Material bucket;

[0032] 42: Syringe;

[0033] 44: Heating module;

[0034] 420: Syringe;

[0035] 422: Lead screw;

[0036] L: Alignment ray;

[0037] M: Lens material;

[0038] O: Optical products;

[0039] P: Positive pressure airflow;

[0040] PO: Preformed optical products;

[0041] S10, S20, S30, S40, S50, S60, S70, S80: Steps;

[0042] T: Light transmission channel. Detailed Implementation

[0043] To enable those skilled in the art to easily understand the contents of this application, the following description, in conjunction with embodiments and accompanying drawings, further illustrates the application. The embodiments are merely illustrative of the technical features of this application, and the content mentioned is not intended to limit the application.

[0044] Please see Figure 1 , Figure 2 , Figure 3 and Figure 4This application provides an optical module molding system, including a preform base 1, an alignment module 2, a mold cover 3, and an injection pump. The preform base 1 includes a light-transmitting channel T that extends through it, and the preform base 1 is used to support an optical product O. The alignment module 2 includes a light emitter 20 and a light detector 22. The light emitter 20 emits alignment light L into the light-transmitting channel T, and the light detector 22 detects the alignment light L. The mold cover 3 is used to combine with the preform base 1 to form an injection molding mold. The injection molding mold includes an injection hole and a mold cavity. The injection hole and the mold cavity are interconnected, so the mold cavity can communicate with the outside world through the injection hole. The injection pump is used to inject molten lens material M into the mold cavity of the injection molding mold through the injection hole.

[0045] Please see Figure 1 , Figure 2 and Figure 3 In one embodiment of this application, the preformed base 1 includes a movable platform 10 and a contouring part 12. The contouring part 12 is disposed on the movable platform 10, and the light-transmitting channel T passes through the movable platform 10 and the contouring part 12. The movable platform 10 can be connected to a robotic arm or an electric multi-axis moving platform. Therefore, the preformed base 1 can be moved by controlling the robotic arm or the electric multi-axis moving platform. The contouring part 12 is used to support the optical product O and to serve as a template in the subsequent preformation step of the optical product O. Under pressure and heating, the optical product O completes the preformation according to the shape of the contouring part 12 to obtain the preformed optical product PO. Therefore, the preformed optical product PO will fit with the contouring part 12 and conform to the curvature of the contouring part 12. In this embodiment, the movable platform 10 is a plate, and the contouring part 12 is a hemispherical configuration formed by the upward protrusion of the movable platform 10. However, in actual implementation, it is not limited to this. In specific implementation, the configuration of the contouring part 12 can be adjusted according to practical needs. In the following embodiments, optical product O is taken as a polarizer, but in actual implementation, it is not limited to this, and optical product O can also be other optical films.

[0046] Please see Figure 1 , Figure 2 and Figure 3In one embodiment of this application, the material of the light-transmitting channel T is polycarbonate, so that the alignment light L can be directed to the optical product O through the light-transmitting channel T, and then pass through the optical product O to reach the light detector 22. However, in actual implementation, it is not limited to this. The material of the light-transmitting channel T can also be polymethyl methacrylate, polystyrene, or transparent glass fiber reinforced plastic, etc., which have light-transmitting properties. In another embodiment of this application, the materials of the movable stage 10, the contouring part 12, and the light-transmitting channel T in the preformed base 1 are all light-transmitting materials, and the movable stage 10, the contouring part 12, and the light-transmitting channel T are integrally formed. Therefore, if the optical product O needs to be cured by a step such as ultraviolet light irradiation, since the entire preformed base 1 is light-transmitting, ultraviolet light can penetrate the preformed base 1 to irradiate the optical product O and cure the optical product O. In another embodiment of this application, the light-transmitting channel T also includes a condenser lens or an optical fiber. The condenser lens is used to concentrate the alignment light L, and the optical fiber is used to assist in the transmission of the alignment light L, so as to reduce the dissipation of the laser when passing through the light-transmitting channel T.

[0047] Please see Figure 1 , Figure 2 and Figure 3 In one embodiment of this application, the surfaces of the contoured portion 12 of the preformed base 1 facing the optical product O and the light-transmitting channel T facing the optical product O further include a light-transmitting hard coating. The material of the light-transmitting hard coating can be titanium dioxide nanoparticles, silicon dioxide nanoparticles, or other high-refractive-index materials, such as zirconium. Covering the surfaces of the contoured portion 12 and the light-transmitting channel T facing the optical product O with the light-transmitting hard coating not only ensures that the surfaces of the contoured portion 12 and the light-transmitting channel T that come into contact with the optical product O remain flat, but also ensures that the surface of the preformed optical product PO obtained after the optical product O is preformed on the contoured portion 12 remains flat. At the same time, the service life of the preformed base 1 is improved through the protection of the high-transmitting hard coating.

[0048] Please see Figure 2In one embodiment of this application, the alignment module 2 is a laser alignment device, the light emitter 20 is a laser emitter, and the light detector 22 is a light intensity detector. The alignment module 2 is used to confirm whether the optical product O is at the correct loading angle. Furthermore, in the following embodiments, the alignment module 2 also includes a polarizer 24, which is a polarizer sheet. The polarizer 24 is used to convert the laser emitted by the light emitter 20 into polarized light, and the light detector 22 is used to detect the light intensity of the laser after passing through the polarizer 24, the light transmission channel T, and the optical product O. In another embodiment of this application, the alignment module 2 also includes a polarizer, which is another polarizer used to help confirm the polarization direction of the laser after passing through the polarizer 24. The above is only an example of the alignment module 2, but it is not limited to this in actual implementation. For example, the laser emitted by the laser emitter is itself polarized light, so there is no need to change the polarization direction of the laser with the polarizer 24 first, but the polarizer can still be used to confirm the polarization direction of the laser light. In addition, the alignment module 2 can also be other modules used to confirm the loading angle of the optical product O, such as a laser interferometer alignment device.

[0049] Please see Figure 1 , Figure 2 , Figure 3 and Figure 4 In one embodiment of this application, the mold cover 3 includes a groove, and the groove of the mold cover 3 faces the contour portion 12 of the preform base 1. In addition, the mold cover 3 is connected to a robotic arm or an electric multi-axis moving platform to move the mold cover 3 using the robotic arm or electric multi-axis moving platform, so that the mold cover 3 and the preform base 1 are combined to form an injection molding mold. The injection molding mold includes a mold cavity and an injection hole. The mold cavity is located between the mold cover 3 and the preform base 1. Since the preform base 1 already carries the preformed optical product PO before the mold cover 3 and the preform base 1 are combined, the preformed optical product PO will be located in the mold cavity after the mold cover 3 and the preform base 1 are combined. The injection hole is located on the injection molding mold and is used for the injection pump to inject the molten lens material M into the mold cavity. In this embodiment, the injection hole is jointly formed by the mold cover 3 and the preform base 1, but in actual implementation, it is not limited to this. The injection hole can also be located on the mold cover 3 or other positions. This application does not particularly limit this.

[0050] Please see Figure 4In one embodiment of this application, the injection pump includes a material tank 40, a syringe 42, and a heating module 44. The syringe 42 includes a syringe barrel 420, a lead screw 422, and a motor (not shown in the figure). One end of the lead screw 422 is located inside the syringe barrel 420, and the other end of the lead screw 422 is connected to the motor. The motor is used to drive the lead screw 422 of the syringe 42 to move. The syringe barrel 420 of the syringe 42 is in communication with the material tank 40. The heating module 44 is disposed outside the syringe barrel 420. The material tank 40 contains lens material M, taking glass as an example. The material tank 40 is used to supply the lens material M to the syringe barrel 420, and the heating module 44 provides heat to the syringe barrel 420. Heat energy melts the lens material M in the syringe 420, turning it into a molten state. The lead screw 422, driven by a motor, is pushed towards the injection hole, injecting the molten lens material M into the mold cavity of the injection molding die. The molten lens material M then cools and solidifies in the mold cavity to form a lens, which is then bonded to the optical product O. In this way, the bonding between the optical product O and the lens can be achieved without optical adhesive. In one embodiment of this application, the heating module 44 is an induction heating coil, but in actual implementation, it is not limited to this and can also be other types of heaters.

[0051] Please refer to the following steps. Figure 5 An optical module forming method includes steps S10, S20, S30, S40, S50, S60, S70 and S80.

[0052] Step S10 provides the optical module forming system as described above;

[0053] Step S20: Place the optical product O on the preformed base 1 at the position corresponding to the light transmission channel T;

[0054] Step S30: Alignment module 2 confirms whether the feeding angle of the optical product O on the preformed base 1 is correct. If it is correct, proceed to step S40; if it is incorrect, return to step S20.

[0055] Step S40 pre-forms the optical product O onto the pre-forming base 1 to form a pre-formed optical product PO;

[0056] Step S50 assembles the preformed base 1 and the mold cover 3 into an injection molding mold, with the preformed optical product PO located in the cavity of the injection molding mold;

[0057] Step S60: The injection pump injects the molten lens material M into the cavity of the injection molding mold through the injection hole;

[0058] In step S70, the molten lens material M is solidified in the cavity of the injection molding mold to form a lens that is bonded to the preformed optical product PO. The preformed optical product PO and the lens together form an optical module.

[0059] Step S80 separates the preformed base 1, the mold cover 3, and the optical module from each other.

[0060] Please see below Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 In one embodiment of this application, the specific steps of the optical module forming method are as follows:

[0061] Step S10 provides the optical module forming system as described above.

[0062] Step S20 involves placing the optical product O on the preform base 1 at a position corresponding to the light transmission channel T. This can be achieved by first clamping the optical product O with a robotic arm or an electric multi-axis moving platform, and then placing the optical product O on the contouring part 12 of the preform base 1. In this embodiment, when the optical product O is placed on the contouring part 12, the center of the optical product O is aligned with the center of the light transmission channel T, meaning the center of the optical product O is located along the axis of the light transmission channel T. However, in practice, it is not limited to center alignment. For example, if a laser interferometer alignment device is used for subsequent alignment, since multiple alignment rays L are required, the number of light transmission channels T will increase accordingly to accommodate the required alignment rays L. Therefore, each light transmission channel T is not limited to one, nor is it necessary to align it with the center of the optical product O. Instead, the number and position of the light transmission channels T can be adjusted according to practical needs.

[0063] Step S30, the alignment module 2 confirms whether the loading angle of the optical product O on the preform base 1 is correct. Specifically, a polarizer 24 is pre-set on the bottom surface of the moving platform of the preform base 1, and the preform base 1 is positioned between the light emitter 20 and the light detector 22. The light emitter 20 of the alignment module 2 emits alignment light L into the light transmission channel T. The laser first passes through the polarizer 24, then through the light transmission channel T and the optical product O, and finally reaches the light detector 22. The light detector 22 then judges the light intensity. Based on the different loading angles of the optical product O, if the polarization direction of the optical product O is different from that of the polarizer... If the polarization direction of 24 is different, the light intensity detected by the light detector 22 will not reach the maximum value. Therefore, the light intensity can be used to confirm whether the loading angle of the optical product O is correct or has a deviation. If the light intensity detected by the light detector 22 does not reach the maximum value, it is determined that the optical product O is not at the correct loading angle and the loading angle is incorrect. Then, return to step S20 to reset the optical product O on the pre-forming base 1 and the position corresponding to the light transmission channel T. Conversely, if the light intensity detected by the light detector 22 reaches the maximum value, it is determined that the loading angle of the optical product O is correct and step S40 is executed.

[0064] Step S40, which involves preforming the optical product O onto the preforming base 1 to form a preformed optical product PO, in this embodiment utilizes a positive pressure airflow P to blow onto the optical product O. The preforming base 1 can be connected to a temperature controller (not shown in the figure) to provide heat energy to the optical product O. Under the heating of the preforming base 1 and the action of the positive pressure airflow P, the optical product O deforms according to the shape of the contouring part 12 of the preforming base 1 to conform to the curvature of the contouring part 12, thereby completing the preforming process of the optical product O and obtaining the preformed optical product PO. The preformed optical product PO is also located on the preforming base. On the contouring part 12 of 1; the positive pressure airflow P can be provided by a positive pressure airflow source, which can be a blower or other device that provides positive pressure airflow P; the aforementioned preforming method is only an example, and is not limited to this in actual implementation. The preforming method can also be to directly provide heated positive pressure airflow P. For example, it can be formed by a gas heater and a positive pressure airflow P source. The positive pressure airflow P source can be a blower. The gas heater heats the airflow generated by the blower to form heated positive pressure airflow P. In addition, pressure can be provided by a contouring head to preform the optical product O on the contouring part 12. This can be adjusted according to practical needs, and this application does not particularly limit it.

[0065] Step S50, which assembles the preformed base 1 and the mold cover 3 into an injection molding mold and places the preformed optical product PO in the cavity of the injection molding mold, involves using a robotic arm to move the mold cover 3 and the preformed base 1 separately and assemble them into an injection molding mold. Since the preformed optical product PO is located on the contour part 12 of the preformed base 1, the preformed optical product PO is located in the cavity of the injection molding mold. The above is only an example. In actual implementation, only the mold cover 3 or only the preformed base 1 may be moved. This application does not have any particular limitations.

[0066] In step S60, the injection pump injects molten lens material M into the mold cavity of the injection molding die through the injection hole. The syringe 420 of the injection pump is connected to the injection hole of the injection molding die. The syringe 420 contains the lens material M provided by the material tank 40. The lens material M in the syringe 420 is melted by the heating module 44, so that the lens material M becomes molten. Then, the motor drives the lead screw 422 to inject the molten lens material M in the syringe 420 into the mold cavity through the injection hole. The molten lens material M fills the mold cavity and covers the pre-formed optical product PO. In this embodiment, the injection pump takes unidirectional horizontal injection as an example, but it is not limited to this in actual implementation. Depending on the number and position of the injection holes on the injection molding die, the injection pump can not only perform unidirectional injection, but also multidirectional injection. Moreover, the injection angle is not limited to the horizontal direction, but can also be the vertical direction or other directions to fill the mold cavity with the molten lens material M.

[0067] In step S70, the molten lens material M is solidified in the cavity of the injection molding mold to form a lens that is bonded to the pre-formed optical product PO. The method in which the pre-formed optical product PO and the lens together form an optical module is to cool the molten lens material M in the mold cavity to become a solid state, thus transforming it into a lens, and the lens is bonded to the pre-formed light-transmitting product to obtain an optical module.

[0068] Step S80, which separates the preformed base 1, the mold cover 3, and the optical module, involves using a robotic arm to move the preformed base 1 and the mold cover 3 separately, separating the preformed base 1 and the mold cover 3. Then, the optical module is demolded by using a robotic arm or by the user holding a tool. The aforementioned steps can then be repeated to continue producing the optical module.

[0069] In summary, this application not only simplifies the optical module manufacturing process by eliminating the use of optical adhesive, but also simplifies the stacking structure of the optical module, allowing for a further reduction in the thickness of the optical module. It also reduces the risk of product defects caused by air bubbles during the adhesive bonding process. Therefore, this application is beneficial for improving the production yield of optical modules and can be applied to wearable display devices, lens assembly, and bonding processes. Examples of wearable display devices include augmented reality (AR) wearable display devices, virtual reality (VR) wearable display devices, and mixed reality (MR) wearable display devices.

Claims

1. An optical module forming system, characterized in that, include: A preformed base includes a light-transmitting channel that penetrates the preformed base. The preformed base is used to support an optical product. The preformed base includes a movable platform and a contouring part. The contouring part is disposed on the movable platform and is used to support the optical product. The light-transmitting channel penetrates the movable platform and the contouring part. The alignment module includes a light emitter and a light detector. The light emitter is used to emit alignment light into the light-transmitting channel, and the light detector is used to detect the alignment light. A mold cover body for combining with the preformed base body to form an injection molding mold, the injection molding mold including an injection hole and a mold cavity, the injection hole and the mold cavity communicating with each other; An injection pump is used to inject molten lens material into the cavity of the injection molding die through the injection hole; The light-transmitting channel passes through the preform base and works with the alignment module to confirm optical alignment before the preformation of the optical product. After alignment is completed, the optical product remains on the preform base and continues to enter the injection molding process in the same process flow.

2. The optical module forming system as described in claim 1, characterized in that, The material of the light-transmitting channel is a light-transmitting material.

3. The optical module forming system as described in claim 1, characterized in that, The light-transmitting channel also includes a condenser lens.

4. The optical module forming system as described in claim 1, characterized in that, The light-transmitting channel also includes optical fibers.

5. The optical module forming system as described in claim 1, characterized in that, The materials of the movable platform, the contouring part, and the light-transmitting channel are all light-transmitting materials.

6. The optical module forming system as described in claim 1, characterized in that, The surface of the preformed base facing the optical product and the surface of the light-transmitting channel facing the optical product also include a light-transmitting hard coating.

7. The optical module forming system as described in claim 1, characterized in that, The injection pump includes a material tank, a syringe, and a heating module. The syringe is connected to the material tank, and the heating module is located on the outside of the syringe. The material tank contains the lens material and is used to supply the lens material to the syringe. The heating module provides heat energy to the syringe, causing the lens material in the syringe to melt into a molten state.

8. A method for forming an optical module, characterized in that, Includes the following steps: Provide an optical module forming system as described in claim 1; The optical product is placed on the preformed base and at the position corresponding to the light transmission channel; The alignment module confirms whether the loading angle of the optical product on the preformed base is correct. If it is correct, it proceeds to the next step; if it is incorrect, it returns to the previous step. Before the preformed base and the mold cover are assembled into the injection molding mold, the optical product is held on the preformed base and preformed into a preformed optical product. The preformed base body and the mold cover body are assembled into the injection molding mold, and the preformed optical product is located in the mold cavity of the injection molding mold; The injection pump injects the molten lens material into the cavity of the injection molding die through the injection hole; The molten lens material is solidified in the cavity of the injection molding die to form a lens that is bonded to the preformed optical product. The preformed optical product and the lens together form an optical module. Separate the preformed base, the mold cover, and the optical module from each other; The optical product is held on the preformed base after alignment and then enters the injection molding step in the same process flow.

9. The optical module forming method as described in claim 8, characterized in that, The molten lens material is formed by heating and melting the lens material using the injection pump.

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