A one-piece molding and bonding method for forming an optical cube by combining two triangular prisms

Abstract

The present invention discloses an integrated forming and bonding method for forming an optical cube by using two triangular prisms, comprising the following steps: S1, placing a lower prism on a supporting structure for fixation; S2, applying a layer of UV glue on the bonding surface of the lower prism; S3, placing a PBS film material on a film material positioning structure for positioning and placement, so that the film material is located above the lower prism; S4, applying a layer of UV glue on the surface of the PBS film material; S5, placing an upper prism on an upper prism positioning mechanism for preliminary positioning and fixation; S6, using an up and down displacement pressing mechanism to adaptively press the upper prism, the PBS film material, the two layers of UV glue, and the lower prism to form an optical cube; S7, turning on a UV lamp, irradiating the optical cube from top to bottom for initial curing; S8, placing the irradiated optical cube into an oven for secondary curing. The bonding method adopts a one-time integrated forming and bonding method, which can ensure the functional effect of the optical cube and minimize the risk of damage to the PBS film material.

Description

Technical Field

[0001] The present invention relates to the technical field of optical prism bonding, and more particularly to a method for integrally forming and bonding two triangular prisms to form an optical cube. Background Art

[0002] A bonded prism is an optical device. Currently, bonded prisms are generally formed by assembling two or more prisms together and then gluing them together using optical industry standard glue. The existing patent application number is CN202311472869.1, and the patent name is a patent for a prism bonding process. It discloses the following steps: placing a PBS film on a first adsorption mechanism, which is used to electrostatically adsorb the PBS film; bonding a prism to the side of the PBS film facing away from the first adsorption mechanism, so that the prism and PBS film form a semi-finished product; separating the semi-finished product from the first adsorption mechanism and flipping the semi-finished product; bonding another prism to the side of the PBS film facing away from the prism.

[0003] This process addresses the thin and sensitive nature of PBS film and the problem of dents that may occur during negative pressure vacuum adsorption and lamination. The electrostatic adsorption of the first adsorption mechanism enables the PBS film to be laminated without moving, thus avoiding dents caused by negative pressure adsorption. However, the process does not explain how to laminate (what glue to use in conjunction with other processes). Furthermore, due to the sensitivity and thinness of PBS film, secondary lamination carries the risk of damaging the PBS film. PBS film also places high demands on the smoothness of the glue and the surface to which it is bonded, and how to ensure smooth lamination is also not explained. Summary of the Invention

[0004] In response to the shortcomings of the existing technology, the present invention provides a one-piece molding and bonding method for forming an optical cube by using two triangular prisms. The bonding method adopts a one-time one-piece molding and bonding method, which can ensure the functional effect of the optical cube and minimize the risk of damage to the PBS film material.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A method for integrally forming and laminating two triangular prisms into an optical cube comprises the following steps:

[0007] S1. Place the lower prism on the supporting structure of the fixture and fix it;

[0008] S2. Apply a layer of UV glue on the bonding surface of the lower prism placed on the supporting structure;

[0009] S3. Place the PBS membrane on the membrane positioning structure of the fixture and position it so that it is above the lower prism;

[0010] S4. Apply a layer of UV glue on the surface of the placed PBS membrane;

[0011] S5. Place the upper prism on the upper prism positioning mechanism of the fixture for preliminary positioning and fixation, so that it is located above the PBS film and ensure that there is no step difference between the upper prism and the lower prism;

[0012] S6. Use the up-and-down displacement pressing mechanism to adaptively press the upper prism, PBS film, two layers of UV glue, and the lower prism to form an optical cube.

[0013] S7, turn on the UV lamp and irradiate the optical cube from top to bottom to perform initial curing;

[0014] S8. Place the irradiated optical cube into an oven for secondary curing.

[0015] Furthermore, in step S6, the position of the upper prism is corrected by the up-and-down displacement pressing mechanism to eliminate the left-right step difference between the upper prism and the lower prism, and the upper prism and the PBS film are pressed down by the weight of the up-and-down displacement pressing mechanism, so that the upper prism, PBS film, two layers of UV glue and the lower prism are adaptively pressed.

[0016] Furthermore, after the PBS film is placed, there is a gap between the PBS film and the lower prism.

[0017] Furthermore, after the upper prism is positioned and fixed, a gap exists between the upper prism and the PBS film material.

[0018] Furthermore, in step S8, UV lamps are arranged above and below the upper prism and the lower prism, and the distances between the UV lamps located above and below and the bonding surfaces of the upper prism and the lower prism are exactly the same.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] The one-piece molding bonding method of the present invention uses a jig to position and fix the upper prism, the lower prism and the PBS film material before bonding, and the three are in a non-contact state. Then, the three are pressed down and bonded by an up-and-down displacement pressing mechanism to achieve one-piece molding bonding. This can effectively solve the front-to-back and left-to-right step differences in the bonding between the prism and the lower prism. While ensuring the accuracy of their positional relationship, it can also ensure the flatness of the bonding surface of the PBS film material. In addition, by using the up-and-down displacement pressing mechanism to perform adaptive pressing, it is ensured that there is always a force to combine the two prisms and the PBS film material together, so that the flatness of the bonding surface of the PBS film material is guaranteed, avoiding peeling caused by the bonding flatness and causing obvious wrinkling, white fog and other phenomena, which may affect the optical performance of the bonded optical cube or even make it unusable.

[0021] At the same time, the UV light irradiation at equal distances above and below ensures that the irradiation energy of the two bonding surfaces is uniform, further ensuring the stability of the PBS film bonding surface, thus showing excellent optical properties;

[0022] After UV light curing, the optical cube is placed in an oven according to the characteristics of the UV glue for further curing, which can eliminate the risk of degumming and peeling, and prevent the PBS film from wrinkling and white fogging. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. Those skilled in the art can also derive other drawings based on these drawings without inventive work, among which:

[0024] Figure 1 A schematic diagram of the one-piece molding and bonding method of two triangular prisms to form an optical cube;

[0025] Figure 2 is a schematic diagram of the optical cube;

[0026] Figure 3 Schematic diagram of the structure of a fixture used to bond two triangular prisms into an optical cube Figure 1 ;

[0027] Figure 4 Schematic diagram of a fixture used to bond two triangular prisms into an optical cube Figure 2 ;

[0028] Figure 5 It is a structural diagram of the upper positioning mechanism, the lower positioning mechanism, and the upper and lower displacement pressing mechanism;

[0029] Figure 6 Schematic diagram of the structure of the upper positioning mechanism and the lower positioning mechanism;

[0030] Figure 7 Schematic diagram of the structure of the up and down displacement pressing mechanism;

[0031] The markings in the figure are: 1. Frame; 2. Base; 201. Supporting groove; 202. Supporting inclined surface; 203. Avoidance hole; 3. Up and down displacement pressing mechanism; 301. Slide; 302. Pressing base; 303. Pressing block; 304. Pressing inclined surface; 305. T-shaped block; 306. Placement table; 307. Locking structure; 4. UV lamp; 5. Elastic fixing part; 501. Sliding column; 502. Top column; 6. Adsorption seat; 601. Adsorption hole; 7. Membrane material placement groove; 8. Upper prism; 9. Lower prism; 10. PBS membrane material; 11. UV glue. DETAILED DESCRIPTION

[0032] In the description of the present invention, it should be noted that, for directional words, such as the terms "center", "horizontal (X)", "longitudinal (Y)", "vertical (Z)", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like, indicating directions and positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and cannot be understood as limiting the specific scope of protection of the present invention.

[0033] Furthermore, 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 technical features. Therefore, the terms "first" and "second" may explicitly or implicitly refer to one or more of these features. Throughout the description of the present invention, "several" and "a number" mean two or more, unless otherwise specifically defined.

[0034] A method for integrally forming and laminating two triangular prisms into an optical cube comprises the following steps:

[0035] S1. Place the lower prism 9 on the supporting structure of the fixture and fix it;

[0036] S2. Apply a layer of UV glue 11 on the bonding surface of the lower prism 9 placed on the supporting structure;

[0037] S3, placing the PBS film 10 on the film positioning structure of the fixture and positioning it so that it is located above the lower prism 9;

[0038] S4. Apply a layer of UV glue 11 on the surface of the placed PBS membrane 10;

[0039] S5. Place the upper prism 8 on the upper prism 8 positioning mechanism of the fixture for preliminary positioning and fixing, so that it is located above the PBS film 10 and ensures that there is no step difference between the upper prism 8 and the lower prism 9;

[0040] S6. Use the up-down displacement pressing mechanism 3 to adaptively press the upper prism 8, the PBS film 10, the two layers of UV glue 11, and the lower prism 9 to form an optical cube.

[0041] S7, turn on the UV lamp 4 and irradiate the optical cube from top to bottom to perform initial curing;

[0042] S8. Place the irradiated optical cube into an oven for secondary curing.

[0043] Preferably, in step S6, the position of the upper prism 8 is corrected by the up-and-down displacement pressing mechanism 3 to eliminate the left-right step difference between the upper prism 8 and the lower prism 9, and the upper prism 8 and the PBS film material 10 are pressed downward by the self-weight of the up-and-down displacement pressing mechanism 3, so that the upper prism 8, the PBS film material 10, the two layers of UV glue 11 and the lower prism 9 are adaptively pressed.

[0044] Preferably, after the PBS film 10 is placed, there is a gap between the PBS film 10 and the lower prism 9 .

[0045] Preferably, after the upper prism 8 is positioned and fixed, a gap exists between the upper prism 8 and the PBS film material 10 .

[0046] Preferably, in step S8 , the UV lamps 4 are arranged above and below the upper prism 8 and the lower prism 9 , and the distances from the upper and lower UV lamps 4 to the bonding surfaces of the upper prism 8 and the lower prism 9 are exactly the same.

[0047] A tooling fixture for bonding two triangular prisms into an optical cube, comprising:

[0048] A frame 1, on which a lower positioning mechanism for positioning and fixing a lower prism 9 and an upper positioning mechanism for positioning and fixing an upper prism 8 are respectively provided;

[0049] The vertical displacement pressing mechanism 3 includes a vertically arranged slide 301, a pressing member, and a self-gravity mechanism. The slide 301 is mounted on the frame 1. The pressing member and the self-gravity mechanism are both mounted on the sliding end of the slide 301, wherein the pressing member is arranged downward;

[0050] Two groups of UV lamps 4 are provided, and the two groups of UV lamps 4 are respectively located above and below the frame 1 for irradiating the upper prism 8 and the lower prism 9 respectively.

[0051] Preferably, the lower positioning mechanism includes a base 2 and an elastic fixing member 5, the base 2 is provided with a supporting groove 201, and supporting inclined surfaces 202 are provided on both sides of the supporting groove 201. The elastic fixing member 5 is located on the side of the supporting groove 201 and is used to fix the lower prism 9 placed in the supporting groove 201.

[0052] Preferably, the elastic fixing member 5 includes a top column 502, a sliding column 501 and a spring. The sliding column 501 is arranged horizontally and is slidably connected to the base 2. One end of the spring is connected to the reference and the other end is connected to the sliding column 501. The top column 502 is connected to the sliding column 501 and is arranged in parallel. One end of the top column 502 can extend into the supporting groove 201 to tighten the lower prism 9.

[0053] Preferably, a sliding hole is provided on the base 2, and an anti-slip structure is provided in the sliding hole. The sliding column 501 is located in the sliding hole, and the sliding column 501 is connected with an anti-slip block. The anti-slip block cooperates with the anti-slip structure to realize the sliding and anti-slipping of the sliding column 501. The spring is sleeved on the sliding column 501, one end of which is connected to the anti-slip block, and the other end is connected to the anti-slip structure of the sliding hole. A tightening hole is also provided on the base 2, and the tightening hole is communicated with the supporting groove 201. One end of the lifting column 502 is connected to the sliding column 501, and the other end passes through the tightening hole and extends into the supporting groove 201.

[0054] Specifically, the lower prism 9 is tightened and fixed by setting a top column 502, a sliding column 501 and a spring structure. The force application area of ​​the top column 502 will not be larger than the side of the prism, thereby protecting the prism from edge collapse during the prism bonding process, and making the lower prism 9 tightly fit on the side wall of its supporting groove 201, eliminating the step difference caused by the upper prism 8 not being placed in place.

[0055] Preferably, the base 2 is provided with film material placement grooves 7 on both sides of the supporting groove 201, and the PBS film material 10 is positioned and placed through the film material placement grooves 7, so that the PBS film material 10 is in a non-contact state with the lower prism 9 after being placed. This structural design of the PBS film material 10 in such a state can effectively prevent the PBS film material 10 from wandering after contacting the UV glue before pressing, and the problem of bubbles forming on the bonding surface.

[0056] Preferably, the supporting groove 201 of the base 2 is located at one end away from the elastic fixing member 5 and is provided with avoidance holes 203 on both sides;

[0057] Specifically, the prism is relatively small, and improper operation during the bonding process may cause stress concentration on the right-angled edge, which may easily lead to edge chipping. Therefore, an avoidance hole 203 is provided at a right angle position of the supporting groove 201 relative to the prism to protect the prism from edge chipping during the bonding process.

[0058] Preferably, the upper positioning mechanism includes an adsorption seat 6, which is mounted on the base 2 and located on a side of the supporting groove 201 away from the elastic fixing member 5. The adsorption seat 6 is provided with an adsorption hole 601 on one side of the supporting groove 201 facing downward, and a connecting hole is provided on the other side of the adsorption hole 601. The connecting hole is connected to an air pump through an air pipe.

[0059] Specifically, the upper prism 8 is placed in front of the adsorption hole 601 so that the upper prism 8 is adsorbed onto the side wall of the adsorption hole 601 of the adsorption seat 6. This prevents the upper prism 8 from contacting the PBS film 10 and the lower prism 9 before lamination, and also prevents the upper prism 8 from contacting the UV glue 11 pre-dotted on the PBS film 10 in advance. This effectively prevents the PBS film 10 from moving after contacting the UV glue before lamination, and prevents bubbles from forming on the bonding surface.

[0060] Moreover, the structural form of the upper positioning mechanism means that the upper prism 8 does not need to be completely positioned. This design facilitates operation and releases the entire operating area of ​​the upper prism 8 for easy observation, allowing for timely handling of possible problems such as excessive glue overflow.

[0061] Preferably, the adsorption seat 6 of the upper positioning mechanism is provided with an open groove at the position of the film material placement groove 7, and the open groove is connected to the film material placement groove 7, so that the PBS film material 10 can be placed sideways through the open groove, thereby avoiding the possibility of touching the glue that has been applied with UV glue when it is placed from the front, causing damage to the process, and achieving the goal of not affecting the glue surface on the lower prism 9, thereby ensuring the stability of the process.

[0062] Preferably, the self-gravity mechanism includes a T-shaped block 305, which is arranged vertically and connected to the sliding end of the slide 301. Placement platforms 306 are provided on both sides of the top of the T-shaped block 305, and the placement platforms 306 are used to place load blocks;

[0063] Specifically, by setting a T-shaped block 305 and setting a placement platform 306 on the top of the T-shaped block 305, the self-gravity mechanism can be self-weighted by placing several load blocks on the placement platform 306, thereby regulating the self-weight downward force.

[0064] Preferably, the pressing member includes a pressing base 302 and two pressing blocks 303, wherein the pressing base 302 is connected to the sliding end of the slide 301, the two pressing blocks 303 are arranged opposite to each other and are detachably connected to the pressing base 302, and a pressing inclined surface 304 is provided at the bottom of the pressing block 303;

[0065] Specifically, by providing a pressing base 302 and two pressing blocks 303, the two pressing blocks 303 are detachably connected to the pressing base 302, so that the pressing blocks 303 can be more accurately matched and calibrated during adjustment and calibration. The two pressing blocks 303 are provided with a 45° pressing slope 304 at the bottom and are arranged relative to each other, so that the surface of the upper prism 8 can be effectively pressed down, and by arranging the two pressing blocks 303 relative to each other at intervals, the middle part of the upper prism 8 can be exposed, so that the UV light from above can be irradiated onto the bonding surface, thereby ensuring the UV light curing effect.

[0066] Preferably, a locking structure 307 is also provided on the sliding end of the slide 301. The locking structure 307 can be a locking bolt. The locking bolt is threadedly connected to the sliding end of the slide 301 and can tighten the slide rail of the slide 301, thereby locking the sliding end of the slide 301.

[0067] Preferably, the distances between the UV lamps 4 above and below the frame 1 and the bonding surfaces of the upper prism 8 and the lower prism 9 are exactly the same, thereby ensuring the irradiation and curing of the UV glue 11, ensuring the light curing effect and the flatness of the bonding surface, and not affecting the PBS film material 10.

[0068] Preferably, the frame 1 is provided with a plurality of upper positioning mechanisms, a lower positioning mechanism, and an up-and-down displacement pressing mechanism 3, and the plurality of upper positioning mechanisms, the lower positioning mechanism, and the up-and-down displacement pressing mechanism 3 are arranged side by side, and the UV lamps 4 located above and below the frame 1 can irradiate the plurality of upper positioning mechanisms and the lower positioning mechanisms, so that the upper and lower UV lamps 4 perform UV light curing on the plurality of upper and lower prisms 9;

[0069] Specifically, by providing a plurality of upper positioning mechanisms, lower positioning mechanisms and upper and lower displacement pressing mechanisms 3 arranged side by side, the tooling fixture can be processed and manufactured in batches, which can greatly save manufacturing time and increase output.

[0070] In this embodiment, the tooling fixture and the bonding method are combined to form an integrated bonding method for forming an optical cube with two triangular prisms, including the following steps:

[0071] S1. Pull out the top post 502 and place the lower prism 9 in the supporting groove 201. Then release the top post 502 to tighten and fix the lower prism 9.

[0072] S2. Apply a layer of UV glue 11 on the bonding surface of the lower prism 9;

[0073] S3, placing the PBS film 10 sideways into the film placement slots 7 on both sides of the supporting slot 201 and across the supporting slot 201, with the PBS film 10 and the lower prism 9 in a non-contact state;

[0074] S4, applying a layer of UV glue 11 on the surface of the PBS membrane 10;

[0075] S5, placing the upper prism 8 on the adsorption hole 601 of the adsorption seat 6, and making the upper prism 8, the PBS film 10 and the lower prism 9 not in contact with each other;

[0076] S6. Lower the pressing piece so that the two pressing blocks 303 press down the upper prism 8, so that the upper prism 8, the PBS film 10, and the lower prism 9 are bonded together. The pressing piece continues to press down slowly, so that the upper prism 8, the PBS film 10, and the lower prism 9 can have an adaptive pressing process.

[0077] S7, turning on the upper and lower UV lamps 4, and performing light curing on the bonded prism, PBS film 10 and lower prism 9 through the upper and lower UV lamps 4 to complete the bonding.

[0078] S8. Remove the optical cube that has been irradiated with UV light from the fixture and place it in an oven for secondary curing.

[0079] The one-piece molding bonding method of the present invention uses a jig to position, place and fix the upper prism 8, the lower prism 9 and the PBS film material 10 before bonding, and the three are in a non-contact state, and then the three are pressed down and bonded by the up-down displacement pressing mechanism 3 to achieve one-piece molding bonding. This can effectively solve the front-to-back and left-to-right step differences between the prism and the lower prism 9, while ensuring the accuracy of their positional relationship. It can also ensure the flatness of the bonding surface of the PBS film material 10, and by using the up-down displacement pressing mechanism 3 to perform adaptive pressing, it is ensured that there is always a force to combine the two prisms and the PBS film material 10 together, so that the flatness of the bonding surface of the PBS film material 10 is guaranteed, avoiding peeling caused by the bonding flatness and causing obvious wrinkling, white fog and other phenomena, which will affect the optical performance of the bonded optical cube or even make it unusable.

[0080] At the same time, the UV light irradiation at the upper and lower equidistant steps ensures that the irradiation energy of the two bonding surfaces is uniform, further ensuring the stability of the bonding surface of the PBS membrane material 10, thereby showing excellent optical properties;

[0081] After UV curing, the optical cube is placed in an oven according to the characteristics of the UV glue 11 for further curing, which can eliminate the risk of debonding and peeling and prevent the PBS film 10 from wrinkling and white fogging.

[0082] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for integrally forming and bonding two triangular prisms to form an optical cube, characterized in that: The steps include: S1. Place the lower prism on the supporting structure of the fixture and fix it; S2. Apply a layer of UV glue on the bonding surface of the lower prism placed on the supporting structure; S3. Place the PBS membrane on the membrane positioning structure of the fixture and position it so that it is above the lower prism; S4. Apply a layer of UV glue on the surface of the placed PBS membrane; S5. Place the upper prism on the upper prism positioning mechanism of the fixture for preliminary positioning and fixation, so that it is located above the PBS film and ensure that there is no step difference between the upper prism and the lower prism; S6. Use the up-and-down displacement pressing mechanism to adaptively press the upper prism, PBS film, two layers of UV glue, and the lower prism to form an optical cube. S7, turn on the UV lamp and irradiate the optical cube from top to bottom to perform initial curing; S8, placing the irradiated optical cube into an oven for secondary curing; The tooling fixture includes: A frame, wherein the frame is provided with a lower positioning mechanism for positioning and fixing the lower prism and an upper positioning mechanism for positioning and fixing the upper prism; An up-and-down displacement pressing mechanism, comprising a vertically arranged slide, a pressing member, and a self-gravity mechanism, wherein the slide is mounted on a frame, and the pressing member and the self-gravity mechanism are both mounted on the sliding end of the slide, wherein the pressing member is arranged downward; There are two groups of UV lamps, one above the rack and one below the rack respectively. The lower positioning mechanism includes a base and an elastic fixing member, the base is provided with a supporting groove, both sides of the supporting groove are provided with supporting inclined surfaces, the elastic fixing member is located on the side of the supporting groove, and the base is provided with film material placement grooves on both sides of the supporting groove; The upper positioning mechanism includes an adsorption seat, which is mounted on the base and located on a side of the supporting slot away from the elastic fixing member. The adsorption seat is provided with an adsorption hole on one side of the supporting slot facing downward, and a connecting hole is provided on the other side of the adsorption hole. The connecting hole is connected to an air pump through an air pipe. The adsorption seat of the upper positioning mechanism is provided with an open groove at the position of the film material placement groove, and the open groove is communicated with the film material placement groove.

2. The method for integrally forming and bonding two triangular prisms to form an optical cube according to claim 1, characterized in that: In step S6, the position of the upper prism is corrected by the up-and-down displacement pressing mechanism to eliminate the left-right step difference between the upper prism and the lower prism, and the upper prism and the PBS film are pressed down by the weight of the up-and-down displacement pressing mechanism, so that the upper prism, the PBS film, the two layers of UV glue and the lower prism are adaptively pressed.

3. The method for integrally forming and bonding two triangular prisms to form an optical cube according to claim 1, characterized in that: After the PBS film is placed, there is a gap between the PBS film and the lower prism.

4. The method for integrally forming and bonding two triangular prisms to form an optical cube according to claim 1, characterized in that: After the upper prism is positioned and fixed, there is a gap between the upper prism and the PBS film material.

5. The method for integrally forming and bonding two triangular prisms into an optical cube according to claim 1, wherein: In step S8, UV lamps are arranged above and below the upper prism and the lower prism, and the distances between the UV lamps located above and below and the bonding surfaces of the upper prism and the lower prism are exactly the same.

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