Spiral Microlens Molding Roller for Precision Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing microlens arrays, such as drilling and roller-cutting, face inefficiencies and inaccuracies in forming dense microlens patterns on a roller surface, with the drilling method being time-consuming and the roller-cutting method prone to alignment errors due to sensor sensitivity and transmission errors.

Innovation Solution

A microlens transcription molding roller with a spiral arrangement of microlens molding surfaces on its outer circumference, allowing continuous machining along a spiral path, eliminating the need for position sensors and reducing machining time by synchronizing roller rotation, tool movement, and tool advancement/retraction steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the drilling method is used to form microlens molding surfaces, then each lens can be formed individually, but the processing time becomes extremely long (around one second per lens)

Engineering Contradiction:

Improvemicrolens molding surface accuracyVSAvoidprocessing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention implements continuous machining by rotating the roller and moving the tool along its circumference without stopping, forming multiple microlens molding surfaces in one continuous operation. This eliminates the repeated stopping and starting inherent in the drilling method, achieving continuous useful action that dramatically increases productivity while maintaining precision through controlled rotation and movement.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The invention employs periodic reciprocating movement of the tool (advancing and retracting at constant cycle) combined with continuous roller rotation. This periodic action allows the tool to engage and disengage from the roller surface rhythmically, forming multiple lenses in sequence while maintaining control over each lens formation process, thus resolving the contradiction between speed and precision.

Inventive Principle:

Principle #19Periodic action

2Productivity

If the roller-cutting processing method is used to form microlens patterns, then processing speed increases, but alignment accuracy deteriorates due to position sensor sensitivity and trigger signal transmission errors

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidlens pattern alignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention replaces the electronic control system (position sensors and trigger signals) with a purely mechanical synchronization system. The tool's reciprocating movement is mechanically coupled to the roller rotation through constant cycle advancement and retraction, eliminating electronic signal transmission errors and sensor sensitivity issues that cause alignment inaccuracies, while maintaining high processing speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system achieves self-synchronization through the mechanical coupling between roller rotation and tool reciprocating movement. The constant cycle of tool advancement and retraction is automatically coordinated with roller rotation without requiring external position sensing or triggering, making the system self-regulating and immune to electronic control errors.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If the roller-cutting method repeatedly stops and moves the diamond tool axially, then complete lens patterns can be formed, but operation efficiency deteriorates due to repeated suspension of processing

Engineering Contradiction:

Improvecomplete lens pattern formationVSAvoidoperation efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The invention maintains continuous roller rotation and continuous tool reciprocating movement along the roller circumference, eliminating the repeated stopping and starting required by conventional methods. The tool continuously engages the roller surface, forming microlens molding surfaces without interruption, thus achieving both complete lens patterns and high operation efficiency through uninterrupted processing.

Inventive Principle:

Principle #20Continuity of useful action

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 highly accurate and efficient formation of dense microlens patterns without alignment errors, improving the optical performance of the resulting microlens optical sheet by ensuring regular and dense microlens distribution.

Implementation Method 1

a tool (21) having an arc tip end... to form a plurality of microlens molding surfaces (5) on an outer circumference of the roller material (7)

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS7988444B2Microlens transcription molding roller and manufacturing method thereof

Publication Date: 2011.08.02 TOSHIBA MASCH CO LTD

AI summary

A microlens transcription molding roller used for transcription-molding a plurality of microlenses on a sheet includes a plurality of microlens molding surfaces arrayed on an outer circumference of the roller along one spiral around an axis of the roller at a constant interval.