Roll Mold Cutting Control for Random Microlens Burr Suppression
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Solution Overview
Problem
Existing methods for manufacturing roll molds with random microlens locations and heights are hindered by the production of burrs, which negatively affect the optical performance of microlens arrays, and there is a lack of accurate technologies for repeatedly cutting the same location multiple times to suppress burr formation.
Innovation Solution
A roll mold manufacturing method and apparatus that utilizes a rotating device with a rotary encoder and a cutting tool stage equipped with a cutting blade, where a control waveform is generated to accurately position and move the cutting blade in a reciprocating motion, allowing for random placement and depth of cut holes, thereby preventing burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cutting depth is increased to form deep cut holes efficiently, then productivity is improved, but burrs are generated on the roll surface which deteriorates manufacturing precision
Solution Approach 1:
The cutting process is divided into multiple stages with decreasing cutting depths. The first cutting process removes material down to a predetermined depth, and subsequent cutting processes remove remaining material in smaller increments. This segmentation prevents burr formation by avoiding excessive cutting depth in a single operation while maintaining overall productivity through automated multi-stage processing.
Solution Approach 2:
The first cutting process is designed to remove the majority of material before subsequent cutting processes. By performing preliminary material removal with a larger cutting depth in the first stage, the patent enables more efficient material removal while reserving smaller, controlled cutting depths for final precision work, thus preventing burrs while maintaining productivity.
2Manufacturing precision
If the same cutting location is cut multiple times to suppress burrs, then manufacturing precision is improved, but the complexity of accurately positioning and repeating cuts increases device complexity
Solution Approach 1:
A detection device detects the rotational position of the roll during cutting operations. This detected position information is fed back to the control device, which uses it to accurately determine and reproduce the same cutting locations across multiple cutting processes. The feedback mechanism enables precise location repetition without requiring complex mechanical positioning systems.
Solution Approach 2:
The patent replaces complex mechanical positioning and repetition mechanisms with a combination of detection and control systems. Instead of using sophisticated mechanical devices to ensure repeated cutting at the same location, the invention uses rotational position detection and electronic control to achieve accurate location repetition, thereby reducing mechanical device complexity.
3Ease of manufacture
If a regular pattern of microlenses is used to simplify manufacturing, then ease of manufacture is improved, but diffraction patterns are generated which deteriorate optical performance
Solution Approach 1:
The patent introduces random variations in the positions and depths of cut holes to create an asymmetric, non-periodic pattern. This randomness eliminates the regularity that causes diffraction patterns while still allowing for simplified manufacturing through automated cutting processes. The asymmetric pattern prevents constructive interference of light waves that would otherwise create diffraction.
Solution Approach 2:
The patent varies parameters such as cut hole position and depth in a random manner rather than using fixed, regular values. By changing these parameters randomly, the invention maintains ease of manufacture through automated control while eliminating the periodic structure that causes diffraction patterns, thus improving optical performance.
Data Source
AI summary
A method for manufacturing a roll mold by cutting a roll, includes generating a control waveform based on a signal corresponding to a rotary position of the roll, and making a plurality of cuts on a surface of the roll by, while the roll is rotated, reciprocating a cutting blade in a radial direction of the roll in accordance with the control waveform. Making the plurality of cuts includes at each of a plurality of predetermined locations, making a predetermined number of cuts of predetermined depth based on the control waveform. Generating the control waveform includes generating a control waveform dictating that the predetermined locations, the predetermined depths, or both are randomly selected. Generating the control waveform includes generating a control waveform dictating that, when multiple cuts are made at a predetermined location, each subsequent cut will have a smaller depth than a preceding cut.