Manufacturing method of double-side cylindrical array convex lens

Abstract

The invention discloses a manufacturing method of a double-side cylindrical surface array convex lens, and relates to the technical field of precise optical element manufacturing, and the method comprises the steps: calculating an assembly standard deviation based on the historical production data of the double-side cylindrical surface array convex lens; based on a normal distribution model, calculating a preset eccentricity according to a preset qualified tolerance zone and the assembly standard deviation; preparing an upper lens plate and a lower lens plate in batches based on the preset eccentricity; and sequentially folding and bonding the upper lens plate and the lower lens plate to prepare the double-side cylindrical array convex lens in batches. According to the method, random errors which cannot be eliminated are converted into controllable systematic errors, so that the effective yield is greatly improved.

Description

Technical Field

[0001] This application relates to the field of precision optical component manufacturing technology, and in particular to a method for manufacturing a double-sided cylindrical array convex lens. Background Technology

[0002] In the field of optical component manufacturing, the double-sided cylindrical array convex lens (i.e., the lens has cylindrical convex lens arrays processed on both sides of the lens) is an important optical component, which is widely used in beam shaping, homogenization, 3D sensing and imaging systems.

[0003] The existing technology employs a pre-processing and then alignment assembly method, which includes the following steps: manufacturing or processing an upper lens plate and a lower lens plate with a cylindrical array separately; during the assembly process, using high-precision mechanical fixtures, a vision alignment system, or a micro-manipulation platform, precisely aligning the central axes (or specific optical references) of the upper and lower lens plates to achieve an ideal concentric or coaxial state; finally, combining the aligned upper and lower lens plates into a complete double-sided cylindrical array lens by means of gluing, welding, or mechanical fixing.

[0004] However, the above assembly method requires extremely high assembly precision and is very costly. To achieve the desired optical performance, the centers of the upper and lower lens arrays must be strictly aligned; any slight translational misalignment will lead to severe optical aberrations such as astigmatism and spot distortion. This requires extremely precise machining equipment and complex alignment processes, significantly increasing manufacturing costs and time. Simultaneously, the yield rate is subject to random errors that are difficult to control. During the assembly process, various random errors are unavoidable, such as mechanical vibration, minor deformation of the fixtures, adhesive shrinkage stress, and subtle differences in operator skill. These random errors result in a random distribution of the final product's alignment state, leading to a large and generally low yield rate (i.e., the proportion of products that fully meet the alignment tolerances), typically only reaching single-digit percentages. This results in unstable product quality and poor economic efficiency for mass production. Furthermore, quality consistency is poor. Since alignment precision depends on the "instantaneous state" of each assembly, even products from the same batch may exhibit significant differences in optical performance, making it difficult to guarantee product consistency and reliability. Summary of the Invention

[0005] The purpose of this application is to provide a method for manufacturing a double-sided cylindrical array convex lens, which transforms unavoidable random errors into controllable systematic errors, thereby significantly improving the effective yield.

[0006] To achieve the above objectives, this application provides the following solution: This application provides a method for manufacturing a double-sided cylindrical array convex lens, including: Based on historical production data of double-sided cylindrical array convex lenses, the assembly standard deviation is calculated. Based on the normal distribution model, the preset eccentricity is calculated according to the preset acceptable tolerance zone and the assembly standard deviation; Based on the preset eccentricity, the upper lens plate and the lower lens plate are manufactured in batches. The upper lens plate and the lower lens plate are sequentially aligned and bonded to mass-produce double-sided cylindrical array convex lenses.

[0007] According to the specific embodiments provided in this application, the following technical effects are disclosed: This application acknowledges and utilizes errors, calculates the assembly standard deviation based on historical production data of the double-sided cylindrical array convex lens, and then determines the preset eccentricity. By introducing a controllable preset eccentricity, the average value of uncontrollable random errors is corrected, so that the error distribution center of the final product is aligned with the quality target. Without significantly increasing equipment costs and process complexity, an order-of-magnitude improvement in yield and deterministic control of product quality are achieved. Attached Figure Description

[0008] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in 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.

[0009] Figure 1 This is a schematic flowchart illustrating a method for manufacturing a double-sided cylindrical array convex lens according to an embodiment of this application.

[0010] Figure 2 This is a probability distribution diagram of eccentricity using traditional methods.

[0011] Figure 3 This is a probability distribution diagram of the eccentricity in this application. Detailed Implementation

[0012] 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.

[0013] This application improves the yield rate by actively introducing and controlling systemic deviations. Specifically, this application overcomes the problem of low yield rate caused by random assembly errors in the prior art. Its core idea is to transform unavoidable random errors into controllable systematic errors, and use statistical methods to screen out qualified products, thereby significantly improving the effective yield rate.

[0014] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0015] In one exemplary embodiment, such as Figure 1 As shown, a method for manufacturing a double-sided cylindrical array convex lens is provided, comprising: Step 100: Calculate the assembly standard deviation based on historical production data of the double-sided cylindrical array convex lens. Specifically, based on historical production data, statistically analyze the actual alignment error distribution of historical batches of double-sided cylindrical array convex lenses under an ideal alignment target, and obtain its standard deviation. .

[0016] Step 200, based on the normal distribution model, according to the preset acceptable tolerance zone [- ,+ The preset eccentricity is calculated based on the assembly standard deviation and the deviation of the assembly standard deviation. The preset eccentricity is determined based on the deviation between the center position of the normal distribution model and the ideal zero point; the ideal zero point is determined based on the preset acceptable tolerance zone; and the preset eccentricity is characterized as a multiple of the assembly standard deviation.

[0017] The preset eccentricity is used to shift the probability distribution center of the total eccentricity of the batch-produced double-sided cylindrical array convex lenses from the original zero point to one side of the original zero point (such as the positive X-axis direction). This can also be understood as systematically shifting the probability distribution center of the total eccentricity of the assembled product (i.e., the double-sided cylindrical array convex lenses) from its original random distribution area to the vicinity of the ideal centering point. Based on this, the mold is precisely designed and processed.

[0018] Step 300: Based on the preset eccentricity, batch-produce the upper lens plate and the lower lens plate; the specific steps are as follows: (31) Based on the preset eccentricity, design the upper mold core and the lower mold core. Specifically, the positioning reference of the cylindrical array cavity located in the lower mold core is coincided with the center of the mold to determine the lower mold core, which is the conventional design method; the center of the cylindrical array cavity located in the upper mold core (equivalent to the physical center of the mold) is coincided with the center of the mold, and then actively offset by the preset eccentricity in a preset direction (such as the positive X-axis direction) to determine the upper mold core, which is the key component for realizing systematic eccentricity.

[0019] With the above design, when the upper and lower molds are closed, the required systematic eccentricity is naturally introduced between the upper and lower lens arrays.

[0020] (32) The clean optical glass preform is placed in the cavity of the lower mold core and precision molded under the set first temperature and first pressure curve to obtain the lower lens plate. After molding, the center of the cylindrical array on the lower lens plate is consistent with the mold reference.

[0021] (33) A clean optical glass preform is placed in the cavity of the upper mold core, and precision molding is performed under the set second temperature and second pressure curves to obtain the upper lens plate. The preparation of the upper lens plate can be carried out under the same process conditions as the preparation of the lower lens plate. At this time, the center of the cylindrical array on the upper lens plate naturally exists relative to the center of the array on the lower lens plate. Systematic offset.

[0022] Step 400 involves sequentially aligning and bonding the upper lens plate and the lower lens plate to mass-produce double-sided cylindrical array convex lenses; specifically including the following steps: (41) When aligning the upper and lower lens plates after molding, instead of repeatedly adjusting to achieve zero eccentricity, a high-precision positioning fixture is used to coarsely position the upper and lower lens plates in a preset direction (consistent with the mold offset direction).

[0023] (42) Using an optical projection or infrared alignment system, the upper lens plate and the lower lens plate after coarse positioning are adjusted a second time. The goal is to adjust the actual alignment error of the upper and lower lens plates to the systematic pre-set eccentricity introduced by the mold. The total eccentricity after superposition is adjusted to near zero to achieve alignment. This is because the mold is pre-set. This alignment operation is easier to implement and less affected by random errors compared to aligning from scratch.

[0024] (43) The upper lens plate and the lower lens plate are bonded together to prepare a double-sided cylindrical array convex lens. The bonding process is optical bonding or direct thermal bonding.

[0025] In one specific application, the method further includes: (1) The batch-produced double-sided cylindrical array convex lenses are inspected to measure the actual total eccentricity of each double-sided cylindrical array convex lens, thus obtaining a new normal distribution. Specifically, a high-precision optical image measuring instrument or a dedicated alignment inspection system is used to perform 100% rapid inspection on the bonded double-sided cylindrical array convex lenses, measuring the actual total eccentricity of each product (i.e., the final alignment error of the upper and lower lens arrays). After collecting the entire batch of data, the total eccentricity will form a distribution with a preset eccentricity value. Centered on, with standard deviation of The normal distribution (determined by inherent random error).

[0026] (2) Based on the new normal distribution, all double-sided cylindrical array convex lenses produced in batches are judged to be qualified. Since the distribution center of the total eccentricity has been systematically shifted to... The product qualification criterion remains that the total eccentricity is close to zero (i.e., within [- ,+ (Within the interval). At this point, the zero point falls in the region where the slope of the shifted distribution curve is relatively large. This is achieved through the optimization in step one. A value that allows the total eccentricity to fall within [- ,+ The probability (i.e., yield) within the specified interval is maximized. Ultimately, by simply selecting products whose measured values ​​fall within the acceptable tolerance zone, a yield significantly higher than that obtained using traditional methods (where the distribution center is at zero) can be achieved.

[0027] like Figure 2 The figure shows the probability distribution of eccentricity using the traditional method. The horizontal axis represents eccentricity, and the vertical axis represents probability density. It is a normal distribution curve centered at a point to the right of zero (representing the average random error). Only a small portion of the left "tail" falls within the qualified zone centered at zero, resulting in a low yield.

[0028] like Figure 3 The figure shown is a probability distribution diagram of the eccentricity in this application. The horizontal axis represents the eccentricity, and the vertical axis represents the probability density. It is a probability density function with a preset eccentricity. The distribution curve is a normal distribution curve centered at zero. The distribution center is moved to a position close to zero, so that the main part of the distribution curve covers the qualified area centered at zero, and the area within the qualified area (i.e. the yield rate) is significantly increased.

[0029] In summary, this application, through its pre-set eccentricity-statistical screening method, steadily increases the yield rate that fully meets the alignment requirements from the traditional 1%-5% level to 10%-20% or even higher. This represents a paradigm shift from "passively accepting random errors" to "actively managing error distribution." In other words, this application acknowledges and utilizes errors, rather than blindly pursuing the unattainable "absolute zero error." Without significantly increasing equipment costs and process complexity, it achieves an order-of-magnitude increase in yield and deterministic control of product quality through a clever approach.

[0030] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0031] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A method for manufacturing a double-sided cylindrical array convex lens, characterized in that, The method includes: Based on historical production data of double-sided cylindrical array convex lenses, the assembly standard deviation is calculated. Based on the normal distribution model, the preset eccentricity is calculated according to the preset acceptable tolerance zone and the assembly standard deviation; Based on the preset eccentricity, the upper lens plate and the lower lens plate are manufactured in batches. The upper lens plate and the lower lens plate are sequentially aligned and bonded to mass-produce double-sided cylindrical array convex lenses.

2. The manufacturing method of the double-sided cylindrical array convex lens according to claim 1, characterized in that, The preset eccentricity is determined based on the deviation between the center position of the normal distribution model and the ideal zero point; the ideal zero point is determined based on the preset acceptable tolerance zone; the preset eccentricity is characterized as a multiple of the assembly standard deviation; The preset eccentricity is used to shift the probability distribution center of the total eccentricity of the batch-produced double-sided cylindrical array convex lenses from the original zero point to one side of the original zero point.

3. The method for manufacturing a double-sided cylindrical array convex lens according to claim 1, characterized in that, Based on the preset eccentricity, the upper lens plate and the lower lens plate are manufactured in batches, including: Based on the preset eccentricity, design the upper mold core and the lower mold core; The optical glass preform is placed in the cavity of the lower mold core and molded under a set first temperature and first pressure curve to obtain the lower lens plate. The optical glass preform is placed in the cavity of the upper mold core and molded under the set second temperature and second pressure curve to obtain the upper lens plate.

4. The method for manufacturing a double-sided cylindrical array convex lens according to claim 3, characterized in that, Based on the aforementioned preset eccentricity, the upper mold core and lower mold core are designed, including: Align the positioning reference of the cylindrical array cavity located in the lower mold core with the mold center to determine the lower mold core mold; The center of the cylindrical array cavity located in the upper mold core is aligned with the center of the mold, and then actively offset by a preset eccentricity in a preset direction to determine the upper mold core mold.

5. The method for manufacturing a double-sided cylindrical array convex lens according to claim 1, characterized in that, The upper lens plate and the lower lens plate are sequentially aligned and bonded to mass-produce double-sided cylindrical array convex lenses, including: The upper lens plate and the lower lens plate are coarsely positioned in a preset direction using a positioning fixture. Using an optical projection or infrared alignment system, the upper lens plate and the lower lens plate, after coarse positioning, are adjusted a second time to achieve alignment; The upper and lower lens plates are bonded together to prepare a double-sided cylindrical array convex lens.

6. The method for manufacturing a double-sided cylindrical array convex lens according to claim 5, characterized in that, The bonding process is either optical bonding or direct thermal bonding.

7. The method for manufacturing a double-sided cylindrical array convex lens according to claim 1, characterized in that, The method further includes: The batch-produced double-sided cylindrical array convex lenses are tested to measure the actual total eccentricity of each double-sided cylindrical array convex lens, and a new normal distribution is obtained. Based on the new normal distribution, all bilateral cylindrical array convex lenses produced in batches are judged to be qualified.

8. The method for manufacturing a double-sided cylindrical array convex lens according to claim 7, characterized in that, The inspection of the double-sided cylindrical array convex lens is carried out using an optical image measuring instrument or an alignment inspection system.

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