Aspherical Lens Molding via Sequential Transfer and Hardening
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Solution Overview
Problem
Conventional methods for manufacturing lenses, such as micro lens arrays, face challenges in achieving high precision, particularly in producing aspherical lenses, due to limitations in molding technologies.
Innovation Solution
A method and apparatus for molding lenses that involve a transfer member with a transfer shape formed equally to or reversely of an aspherical lens portion, where the article to be molded is transformed, hardened, and the transfer member moves to different positions, allowing for repeated contact and separation to achieve precise molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding methods are used to manufacture lenses, then the manufacturing process is simple, but the manufacturing precision is insufficient for high-precision lenses such as aspherical lenses
Solution Approach 1:
The molding process is divided into multiple sequential transfer steps, where a transfer member with a transfer shape contacts different positions of the article to be molded in sequence. Each transfer step imprints the transfer shape onto a new position, enabling high-precision aspherical lens formation through repeated contact and separation cycles
Solution Approach 2:
The transfer member is designed to move dynamically between different positions of the article to be molded. The relative movement between the transfer member and the article enables sequential imprinting of the transfer shape, transforming a static molding process into a dynamic one that achieves higher precision
2Manufacturing precision
If the transfer member contacts the article to be molded at multiple positions, then the manufacturing precision improves, but the molding time increases
Solution Approach 1:
The transfer member continuously contacts different positions of the article to be molded in a sequential manner without interruption. The hardening step is performed at each position before moving to the next, creating a continuous process that maintains precision while optimizing time efficiency through uninterrupted sequential operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of higher precision lenses and associated stampers, improving the precision and accuracy of molded articles like aspherical lenses beyond conventional capabilities.
Implementation Method 1
a hardening step of hardening at least a transformed portion of the article to be molded
Data Source
AI summary
Molded articles, such as a lens, are produced by multiple repetitions of a transfer process composed of the transformation step of bringing a transfer member (62) provided with a transfer configuration area consisting of the same configuration as that of a lens part with aspherical configuration or the configuration opposed to the lens part with aspherical configuration into contact with a photohardening resin to thereby transform the photohardening resin in conformity with the transfer configuration of the transfer member (62); the hardening step of irradiating at least a transformed area of the transformed photohardening resin with light by the use of a light irradiation unit (60) to thereby attain hardening; and the departing step of letting the photohardened resin and the transfer member depart from each other.