BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematically illustrated sectional view of a production device which is a first embodiment of the present invention;
FIG. 2 is a perspective view of the production device of the first embodiment;
FIG. 3 is an enlarged sectional view taken along the line III-III of FIG. 2;
FIG. 4 is a schematic view showing an advantageous releasing effect exhibited by a roughed circular top surface of an upper glass mold;
FIGS. 5 to 8 are sectional views of the production device of the first embodiment, showing successive steps for producing a lens;
FIG. 9 is a schematically illustrated sectional view of a production device which is a second embodiment of the present invention;
FIG. 10 is a perspective of the producing device of the second embodiment;
FIG. 11 is an enlarged sectional view taken along the line XI-XI of FIG. 10;
FIG. 12 is an enlarged schematic and partial view of the production device of the second embodiment, showing an advantageous effect exhibited by an annular ridge possessed by lower glass mold;
FIG. 13 is a perspective view showing a modification of the annular ridge;
FIG. 14 is a view similar to FIG. 13, showing another modification of the annular ridge;
FIGS. 15 to 18 are sectional views of the production produce of the second embodiment, showing successive steps for producing a lens;
FIG. 19 is a schematically illustrated sectional view of a production device which is a third embodiment of the present invention;
FIG. 20 is a plan view of a centering sleeve used in the production device of the third embodiment;
FIG. 21 is a plan view of a modification of the centering sleeve usable in the production device of the third embodiment;
FIGS. 22 to 26 are sectional views of the production device of the third embodiment, showing successive steps for producing a lens;
FIG. 27 is a schematically illustrated sectional view of a production device of a fourth embodiment of the present invention;
FIG. 28 is a view similar to FIG. 27, but showing a production device of a fifth embodiment of the present invention;
FIG. 29 is a schematically illustrated sectional view of a conventional production device;
FIG. 30 is a sectional view of the conventional production device in an assembled condition; and
FIG. 31 is a sectional view of a lens that is produced by the conventional production device.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
For ease of understanding, various directional terms, such as, right, left, upper, lower, rightward and the like will be used in the following description. However, such terms are to be understood with respect to a drawing or drawings on which a corresponding element or portion is shown.
Referring to FIGS. 1 to 8, there is shown a production device 1 of a first embodiment of the present invention, which produces a lens as an optical element.
As is seen from FIG. 1, the production device 1 comprises an upper glass mold 2, a lower glass mold 3 and a centering sleeve 4 by which the upper and lower glass molds 2 and 3 are centered and positioned to each other. The upper and lower glass molds 2 and 3 are constructed of a glass material that shows a high transmittance to an ultraviolet ray. For such glass material, synthetic quartz may be used as well as other glass materials.
As will be understood from FIG. 1, for centering the upper and lower glass molds 2 and 3, mutually facing smaller diameter portions of these molds 2 and 3 are inserted into a bore of the centering sleeve 4.
Although not shown in the drawing, a holding device is employed for holding the two molds 2 and 3 in a vertical direction.
As shown in FIG. 1, mutually facing portions 5 and 5′ of the upper and lower glass molds 2 and 3 are formed with respective recesses with concave molding surfaces 6 and 6′ by which a lens proper portion 102 (see FIG. 8) of a lens 101 is produced as will be described in detail hereinafter.
Furthermore, as is seen from FIG. 1, the mutually facing portions 5 and 5′ of the two glass molds 2 and 3 are formed with respective circular top surfaces 7 and 7′ by which a circular flange portion 103 (see FIG. 8) of the lens 101 is produced as will be clarified hereinafter.
The molding surface 6 or 6′ of each glass mold 2 or 3 is spherical or aspherical in shape, and the circular top surface 7 or 71 of each glass mold 2 or 3 is entirely flat and constructed to surround the corresponding concave recess 6 or 6′.
As shown in FIG. 8, the lens 101 thus produced comprises the lens proper portion 102 that is an optically functional portion and the circular flange portion 103 that is an optically non-functional portion. That is, when the lens 101 is set in a lens-barrel (not shown), the circular flange portion 103 serves as a mounting edge fixed to an inner cylindrical wall of the lens-barrel.
As will be understood from FIGS. 1 to 3, particularly FIG. 3, the circular top surface 7 of the upper glass mold 2 is roughened as compared with the circular top surface 7′ of the lower glass mold 3.
That is, the molding surface 6 of the upper glass mold 2 and the top surface 7′ and molding surface 6′ of the lower glass mold 3 are polished like a mirror finished surface in a range of about 20 nm in Ra Standard, while the top surface 7 of the upper glass mold 2 is finished or dressed in a range of about 12.5 μm in Ra Standard. The roughened top surface 7 of the upper glass mold 2 is produced by employing a sand blast method, a satin finish method or the like.
As is described hereinabove, the circular top surface 7 of the upper glass mold 2 is finished rougher than the circular top surface 7′ of the lower glass mold 3.
This is because of causing the upper glass mold 2 to exhibit a much easier releasing property against a product (viz., the lens 101) than the lower glass mold 3.
As will be described in detail hereinafter, upon molding of the lens 101, the mirror finished circular top surface 7′ of the lower glass mold 3 intimately contacts the product (or lens) 101 establishing a so-called optical contact state therebetween, and thus, the lower glass mold 3 is not easily released from the product or lens 101.
While, as is understood from FIG. 4, in case of the upper glass mold 2, there are inevitably produced great numbers of blank portions 9 at bottoms of the fine cuts 8, which are not filled with an ultraviolet-curing resin 301. That is, the roughened top surface 7 of the upper glass mold 2 does not intimately contact the product (or lens) 101 and thus does not establish the optical contact state therebetween. This means that the upper glass mold 3 is easily released from the product (or lens) 101 as compared with the upper glass mold 2.
In the following, successive steps of producing the lens 101 by practically using the above-mentioned production device 1 will be described in detail with the aid of the drawings.
First, the upper and lower glass molds 2 and 3 are dismantled from the centering sleeve 4 as is seen from FIG. 1, and then a given amount of non-cured ultraviolet-curing resin 301 is put in the concave recess (6′) of the lower glass mold 3, and then the upper and lower glass molds 2 and 3 are properly set in the centering sleeve 4. Thus, the resin 301 is compressed by the upper and lower glass molds 2 and 3 thereby being shaped into a form of the shaped clearance defined between the mutually facing portions 5 and 5′ of the upper and lower glass molds 2 and 3, as is seen from FIG. 5.
Then, as is seen from FIG. 6, ultraviolet rays “UV” are applied to the resin 301 in the shaped clearance for a given time through the upper and lower glass molds 2 and 3 to cure and harden the resin 301. With this curing step, the ultraviolet-curing resin 301 becomes hardened in the production device 1. That is, a product (or lens) 101 is produced and left in the production device 1.
Then, as is seen from FIG. 7, de-molding is carried out by moving the upper glass mold 2 upward together with the centering sleeve 4. Under this step, the lower glass mold 3 is kept fastened.
As is mentioned hereinabove, because of the advantageous releasing ability of the roughened circular top surface 7 of the upper glass mold 2, the releasing of the upper glass mold 2 from the product 101 is easily and smoothly carried out. Since the circular top surface 7′ of the lower glass mold 3 is polished like a mirror finished surface, the product 101 is forced to remain in the lower glass mold 3.
Then, as is seen from FIG. 8, the product 101 is removed from the lower glass mold 3. If this product releasing is not easily or smoothly made, the circular top surface 7′ of the lower glass mold 3 may be somewhat or partially roughened.
The product 101 is then subjected to a cleaning process for cleaning the lens proper portion 102 of the product 101. With this, the lens 101 is finally produced.
As is seen from FIG. 8, the circular flange portion 103 of the product (or lens) 101 thus removed from the production device 1 has a roughened upper surface 103a and a smoothed lower surface 103b.
Since the circular flange portion 103 has upper and lower surfaces 103a and 103b that are different in appearance, it is easy to discriminate the front and rear sides of the product (or lens) 101.
In the above-mentioned first embodiment, the top surface 7 of the upper glass mold 2 is roughened and the top surface 7′ of the lower glass mold 3 is polished. However, if desired, the top surface 7 of the upper glass mold 2 may be polished and the top surface 7′ of the lower glass mold 3 may be roughened. In this case, the product (or lens) 101 is enforcedly remained in the upper glass mold 2.
In the above-mentioned first embodiment, the top surface 7 of the upper glass mold 2 is entirely roughened. However, if desired, the top surface 7 may be partially roughened.
Referring to FIGS. 9 to 18, there is shown a production device 11 of a second embodiment of the present invention, which produces a lens as an optical element.
As is seen from FIG. 9, like in the above-mentioned first embodiment 1, the production device 11 of this second embodiment comprises an upper glass mold 12, a lower glass mold 13 and a centering sleeve 14 by which the upper and lower glass molds 12 and 13 are centered and positioned to each other.
As shown in FIG. 9, mutually facing portions 15 and 15′ of the upper and lower glass molds 12 and 13 are formed with respective recesses with concave molding surfaces 16 and 16′ by which a lens proper portion 112 (see FIG. 18) of a lens 111 is produced as will be described in detail hereinafter.
Furthermore, as is seen from FIG. 9, the mutually facing portions 15 and 15′ of the two glass molds 12 and 13 are formed with respective circular top portions 17 and 17′ by which a circular flange portion 113 (see FIG. 18) of the lens 111 is produced as will be clarified hereinafter.
The molding surface 16 or 16′ of each glass mold 12 or 13 is spherical or aspherical in shape, and the circular top portion 17 or 17′ of each glass mold 12 or 13 is constructed to surround the corresponding concave recess 16 or 16′.
As shown in FIG. 9, the circular top portion 17 of the upper glass mold 12 is entirely flat, while the circular top portion 17′ of the lower glass mold 13 has a stepped surface.
That is, the circular top portion 17′ of the lower glass mold 13 comprises a first circular flat base surface 17′b, a second circular flat top surface 17′c and a cylindrical wall 17′a by which the first and second circular flat surfaces 17′b and 17′c are separated in an axial direction.
It is to be noted that the shape or construction of the circular top portion 17′ of the lower glass mold 13 is made by providing the circular flat surface (or first circular flat base surface) 17′b with a smaller diameter annular ridge 18, as shown in the drawing.
As is described hereinabove, the circular top portion 7′ of the lower glass mold 13 has a much complicated construction as compared with the circular top portion 7 of the upper glass mold 12.
This is because of causing the lower glass mold 13 to exhibit a much difficult releasing property against a product (viz., the lens 111) than the upper glass mold 12.
FIG. 12 is a schematic and partial view of the production device 11 of the second embodiment, by which the much difficult releasing property possessed by the lower glass mold 13 is depicted.
When an ultraviolet-curing resin 301 contained in a cavity defined by the concave recesses 16 and 16′ of the upper and lower glass molds 12 and 13 is being cured by ultraviolet rays, the resin 301 is subjected to a certain contraction as is indicated by arrows. As is seen from the drawing, such contraction is directed to a center portion of the resin 301 and the contraction degree is generally proportional to a thickness of the resin 301.
As shown, during the contraction, a part “P” of the resin 301 is pressed inevitably against an outer cylindrical wall (viz., cylindrical wall 17′a) of the annular ridge 18 of the lower glass mold 13, which strengthens a binding or bonding between the resin 301 and the lower glass mold 13. Thus, releasing the product (or lens) 111 from the lower glass mold 13 becomes difficult as compared with that from the upper glass mold 12.
Of course, the biding or bonding between the resin 301 and the lower glass mold 13 increases as the height of the annular ridge 18 increases. However, if the height is excessive, the annular ridge 18 becomes fragile.
FIG. 12 depicts a dimensional connection between the annular ridge 18 and the circular flange portion 113 of the lens 111, by which the above-mentioned fragility of the annular ridge 18 is suppressed or at least minimized.
That is, in order to suppress or minimize the fragility of the annular ridge 18, the following inequality should established:
H<1/2 T (1)
W<1/2 T (2)
wherein:
- H: height of annular ridge 18
- W: width of annular ridge 18
- T: thickness of circular flange portion 113
If desired, the annular ridge 18 may have modifications which are shown in FIGS. 13 and 14.
In the modification of FIG. 13, a plurality of arcuate projections 18′ are used in place of the annular ridge 18.
While, in the modification of FIG. 14, an annular groove 19 is used in place of the annular ridge 18.
In the following, a method of producing the lens 111 by practically using the above-mentioned production device 11 will be described in detail with the aid of the drawings.
First, as is seen from FIG. 9, the upper and lower glass molds 12 and 13 are dismantled from the centering sleeve 14, and then a given amount of non-cured ultraviolet-curing resin 301 is put in the concave recess (16′) of the lower glass mold 13, and then the upper and lower glass molds 12 and 13 are properly set in the centering sleeve 14, as is seen from FIG. 15. Thus, the resin 301 is compressed by the upper and lower glass molds 12 and 13 thereby being shaped into a form of the shaped clearance defined between the mutually facing portions 15 and 15′ of the upper and lower glass molds 12 and 13.
Then, as is seen from FIG. 16, ultraviolet rays “UV” are applied to the resin 301 in the shaped clearance for a given time through the upper and lower glass molds 12 and 13 to cure and harden the resin 301. With this curing step, the ultraviolet-curing resin 301 becomes hardened in the production device 11. That is, a product (or lens) 111 is left in the production device 11.
Then, as is seen from FIG. 17, de-molding is carried out by moving the upper glass mold 12 upward together with the centering sleeve 14. Under this step, the lower glass mold 13 is kept fastened.
As is mentioned hereinabove, because of the advantageous releasing difficulty of the circular top portion 17′ of the lower glass mold 13, the above-mentioned de-molding action instantly brings about releasing of the upper glass mold 12 from the product 111. That is, the product 111 is forced to remain in the lower glass mold 13.
Then, as is seen from FIG. 18, the product 111 is removed from the lower glass mold 13.
The product 111 is then subjected to a cleaning process for cleaning the lens proper portion 112 of the product 111. With this cleaning process, the lens 111 is finally produced.
As is seen from FIG. 18, the circular flange portion 113 of the product (or lens) 111 thus removed from the production device 11 has an entirely flat upper surface 113a and a grooved lower surface 113b. The groove is denoted by numeral 114 in the drawing.
Since the circular flange portion 113 has upper and lower surfaces 113a and 113b that are different in appearance, it is easy to discriminate the front and rear sides of the product (or lens) 111.
In the above-mentioned second embodiment, the circular top portion 17 of the upper glass mold 12 is entirely flat and the circular top portion 17′ of the lower glass mold 13 is provided with the annular ridge 18. However, if desired, the circular top portion 17 of the upper glass mold 12 may be provided with such annular ridge 18 and the circular top portion 17′ of the lower glass mold 13 may be entirely flat. In this case, the product (or lens) 111 is enforcedly remained in the upper glass mold 12.
Referring to FIGS. 19 to 26, there is shown a production device 21 of a third embodiment of the present invention, which produces a lens as an optical element.
As is seen from FIG. 19, like in the above-mentioned first and second embodiments 1 and 11, the production device 21 of this third embodiment comprises an upper glass mold 22, a lower glass mold 23 and a centering sleeve 24 by which the upper and lower glass molds 22 and 23 are centered and positioned to each other.
As shown in FIG. 19, mutually facing portions 25 and 25′ of the upper and lower glass molds 22 and 23 are formed with respective recesses with concave molding surfaces 26 and 26′ by which a lens proper portion 122 (see FIG. 26) of a lens 121 is produced as will be described in detail hereinafter.
Furthermore, as is seen from FIG. 19, the mutually facing portions 25 and 25′ of the two glass molds 22 and 23 are formed with respective circular top surfaces 27 and 27′ by which a circular flange portion 123 (see FIG. 26) of the lens 121 is produced as will be clarified hereinafter.
The molding surface 26 or 16′ of each glass mold 22 or 23 is spherical or aspherical in shape, and the circular top surface 27 or 27′ of each glass mold 22 or 23 is constructed to surround the corresponding concave recess 26 or 26′.
As shown in FIG. 19, the circular top surface 27 or 27′ of each glass mold 22 or 23 is entirely flat.
Furthermore, as is seen from FIG. 19, the centering sleeve 24 is formed at a cylindrical inner wall thereof with an annular ridge 28.
As is seen from FIG. 22, when the upper and lower glass molds 22 and 23 are properly put into the centering sleeve 24, the circular top surface 27 of the upper glass mold 22 intimately contacts an upper surface of the annular ridge 28, while the circular top surface 27′ of the lower glass mold 23 fails to contact a lower surface of the annular ridge 28 thereby leaving a certain flat clearance therebetween.
With this measure, the product (or lens) 121 is enforcedly remained in the lower glass mold 23 upon de-molding, as will be described in detail hereinafter.
It is now to be noted that as is shown in FIG. 19, the annular ridge 28 of the centering sleeve 24 and the circular top surface 27 of the upper glass mold 21 have a dimensional connection therebetween, which is:
W1<W2 (3)
wherein:
- W1: width of annular ridge 28
- W2: width of circular top surface 27
If desired, the annular ridge 28 may have a modification which is shown in FIG. 21. As shown, in this modification, a plurality of arcuate projections 28′ are used in place of the annular ridge 28.
In the following, a method of producing the lens 121 by practically using the above-mentioned production device 21 will be described in detail with the aid of the drawings.
First, as is seen from FIG. 19, the upper and lower glass molds 22 and 23 are dismantled from the centering sleeve 24, and then a given amount of non-cured ultraviolet-curing resin 301 is put in the concave recess (26′) of the lower glass mold 23, and then as is seen from FIG. 22, the upper and lower glass molds 22 and 23 are properly set in the centering sleeve 24. Thus, the resin 301 is compressed by the upper and lower glass molds 22 and 23 thereby being shaped into a form of the shaped clearance defined between mutually facing portions 25 and 25′ of the upper and lower glass molds 22 and 23.
As is seen from FIG. 22, under this condition, the annular top surface 27 of the upper glass mold 22 intimately contacts the annular ridge 28, while the annular top surface 27′ of the lower glass mold 23 is kept away from the annular ridge 28 leaving therebetween a certain flat clearance in which part of the resin 301 is received.
Then, as is seen from FIG. 23, ultraviolet rays “UV” are applied to the resin 301 in the shaped clearance for a given time through the upper and lower glass molds, 22 and 23 to cure and harden the resin 301. With this curing step, the ultraviolet-curing resin 301 becomes hardened in the production device 21. That is, a product (or lens) 121 is left in the production device 21.
Then, as is seen from FIG. 24, de-molding is carried out by moving the upper glass mold 22 upward. Under this step, the centering sleeve 24 and the lower glass mold 23 are kept fastened.
Because of provision of the annular ridge 28 of the centering sleeve 24, the cured resin 301, viz., the product 121 is left in a unit that includes the lower glass mold 23 and the centering sleeve 24, as shown.
Then, as is seen from FIG. 25, the centering sleeve 24 is moved up from the lower glass mold 23 and put into the upper glass mold 22. With this, the product 121 is remained in the lower glass mold 23.
As is seen from FIG. 24, since the contact surface of the annular ridge 28 relative to the circular flange portion 123 of the product 121 is smaller than that of the circular top surface 27′ of the lower glass mold 23 relative to the circular flange portion 123, the centering sleeve 24 is smoothly released from the product 121 that is left on the lower glass mold 23.
Then, as is seen from FIG. 26, the product 121 is removed from the lower glass mold 23.
The product 121 is then subjected to a cleaning process to become a finished lens.
As is described hereinabove, due to the difference in contact area between the annular ridge 28 of the centering sleeve 24 and the circular top surface 27′ of the lower glass mold 23 relative to the circular flange portion 123 of the product 121, the product 121 is remained on the lower glass mold 23 even when the centering sleeve 24 is moved upward. This facilitates the process of producing the product 121.
As is understood from FIG. 26, the circular flange portion 123 of the product 121 has upper and lower surfaces 123a and 123b that are different in appearance. That is, an annular step 124 is formed on the upper surface 123a in a manner to surround the lens proper portion 122. Thus, it is easy to discriminate the front and rear sides of the product (or lens) 121.
Although the production devices 1, 11 and 21 of the above-mentioned first, second and third embodiments are constructed to produce a so-called biconvex lens 101, 111 or 121, the present invention is also applicable to production devices such as the device 31 as shown in FIG. 27 that produces a so-called meniscus lens 131 and the device 41 as shown in FIG. 28 that produces a so-called biconcave lens 141.
In the above-mentioned embodiments, ultraviolet-curing resin is used as a material of the optical element. Other type resins that become hardened when receiving radial rays may be used as the material. In the above-mentioned embodiments, the upper and lower molds used are produced from glass. But, if desired, such molds may be produced from other materials so long as they permit penetration of the radial rays.
It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and other factors insofar as they are within the scope of the appended claims or the equivalents thereof.
Patent Application
20080055736
