201041712 六、發明說明： 【發明所屬之技術領域】 [0001] 本發明涉及光學元件之製造，尤其涉及用於壓印成型微 小凹透鏡陣列之模仁、模壓裝置以及方法。 【先前技術】 [0002] 目前，很多光學元件，例如折射元件、衍射元件等都採 用壓印成型（請參見The Novel Fabrication Method and Optimum Tooling Design Used for Microlens Arrays ， Proceedings of the 1st 〇 IEEE International Conference on Nano/Micro Engineered and Molecular Systems ； January 1 8-21,2006，Zhuhai, China)之方式生產。壓印成 型是指先將液態或塑性變形材料i敷在基底上，再以壓 印模具壓印成型》 [0003] 請參閱圖1，在製造凹透鏡時，或者其他具有凹面之透鏡 :1 ' t -: t ? t ，例如新月形透鏡或複曲面透鏡時，可採用以下方法： ip I s'" 〇 提供一透明基板10，根據要製邊之凹透鏡12之光學區域 (使光線通過之區域）’即凹透鏡表面，製成模仁14， 模仁14包括一個成型面140，其正好和凹透鏡12之表面形 狀相反’呈向外凸起之表面。在透明基板1〇上塗覆成型 材料’將模仁14壓向成型材料，由於成型面140向模仁14 以外突出，因而對成型材料造成擠壓，使得一部分成型 材料向四周溢出，熱固化或紫外光固化後，這些溢出成 型區域之部分使得凹透鏡12之凹透鏡表面之外之非光學 區120之面積過大，厚度過厚，在後期之進一步加工中， 098117614 表單編號Α0101 第3頁/共17頁 0982029921-0 201041712 因此對成型材料造 [0004] [0005] [0006] [0007] 098117614 需要對不定形部分進行打磨或切削， 成浪費，增加了生產成本。 特別地，當凹透鏡之尺寸越來越小，例如小到微米級或 毫米級大小時，對精度要求也越來越高，一次性製造多 個排列有序或無序之微小凹透鏡時，由於每個成型面140 壓印區域之外都溢出了不少成型材料，因此相鄰兩個凹 透鏡12之間會堆積不少成型材料，也會出現非光學區面 積過大，厚度過厚之問題，而且使得凹透鏡之精度大幅 下降，因此更要儘量減少成型材料溢出現象，減少浪費 〇 【發明内容】 有鑒於此，有必要提供一種可節約成型材料之壓印成型 微小凹透鏡陣列之模仁、模壓裝置以及方法。 一種壓印成型微小凹透鏡陣列之模仁，該模仁具有一個 表面，該表面形成有多個間隔體，每個間隔體之端部具 有頂面，各個間隔體之頂面和該表面平齊，每個間隔體 限定一個用於成型微小凹透鏡之模壓腔，該模壓腔内設 有凸面形模壓面，該凸面形模壓面從該模壓腔之底部向 外凸起，該凸面形模壓面之最高點低於該間隔體之頂面 0 一種壓印成型微小凹透鏡陣列之模壓裝置，包括模仁及 用於承載成型材料之基板；該模仁具有一個表面，該表面 形成有多個間隔體，每個間隔體之端部具有頂面，各個 間隔體之頂面和該表面平齊，使得該模仁在壓印時該間 隔體之頂面能夠平齊地抵壓到該基板；每個間隔體限定 表單編號A0101 第4頁/共17頁 201041712 一個用於成型微小凹透鏡之模壓腔，該模壓腔内設有凸 面形模壓面，該凸面形模壓面從該模壓腔之底部向外凸 起，該凸面形模壓面之最高點低於該間隔體之頂面。 [0008] 一種壓印成型微小凹透鏡陣列之方法，其包括以下步驟 [0009] 提供一基板，該基板具有一承載面； [0010] 于該承載面塗布成型材料； [0011] 提供一模仁，該模仁具有一個表面，該表面形成有多個 間隔體，每個間隔體之端部具有頂面，各個間隔體之頂 面和該表面平齊，每個間隔體限定一個用於成型微小凹 透鏡之模壓腔，該模壓腔内設有凸面形模壓面，該凸面 形模壓面從該模壓腔之底部向外凸起，該凸面形模壓面 之最高點低於該間隔體之頂面； [0012] 將該模仁壓向該承載面，使該模仁之間隔體之頂面直接 與該承載面抵壓，從而在該模仁之各個模壓腔内獲得凹 〇 透鏡預形體； [0013] 固化該凹透鏡預形體； [0014]脫模。 [0015] 與現有技術相比較，本發明提供之模仁之凸面形模壓面 被分別設置在由間隔體所限定之模壓腔内，因此可以將 成型材料限定在模壓腔内而不容易被擠壓到模壓腔之外 ，最大限度地減少對成型材料之浪費；相應地，利用該 模壓裝置製造微小凹透鏡陣列之模壓裝置及方法也可以 0982029921-0 098117614 表單編號A0101 第5頁/共17頁 201041712 最大限度地減少對成型材料之浪費。 【實施方式】 [〇〇16]下面將結合附圖對本發明作進一步詳細說明。 [0017] 請參閱圖2、圖3和圖4 ’本發明實施例提供之模仁2具有 一個表面20 ’表面20形成有多個相互間隔之間隔體36， 每個間隔體36之端部具有頂面，該頂面360和表面20 平齊，每個間隔體36限定一個用於成型微小凹透鏡之模 壓腔34，每個模壓腔34内設有一個凸面形模壓面26。由 於間隔體36是重複結構，每顧間隔I艘3 6所在之模仁部分 可以視為模仁2之單體。 [0018] 所述“微小”凹透鏡是指尺寸小之四透鏡，一般為微米 級或毫米級大小。 [0019] 在本實施例中，間隔體36為環體或者說是中空之圓柱體 ，其也可以是由内外兩個矩形圍成之“回，，字體，也可 以是其他閉合曲線所形成之結構6總之，每個間隔體3 6 獨立地限定一個模壓腔3 4。 [0020] s亥多個間隔體3 6在位置上可以相接，也可以相距一定距 離，距離長短根據需要而定。該多個間隔體36可以有序 排列或者無序排列，對應得到之是一次性形成之由多個 有序排列或無序排狀微小凹透鏡所組成之微小凹透鏡 陣列。 [0021] 098117614 凸面形模壓面26由該模Μ腔34底部向外凸起，該凸面形 模壓面26之最馬點低於頂面36〇。在本實施例中，該凸面 形模壓面26之頂點〇低於該間隔體％之頂面36〇。如果凸 表單編號Α_ 苐6頁/共17頁 0982029921-0 201041712 [0022] Ο [0023] [0024]201041712 VI. Description of the Invention: [Technical Field] The present invention relates to the manufacture of optical components, and more particularly to a mold, a molding apparatus and a method for imprinting a micro concave lens array. [Prior Art] [0002] At present, many optical components, such as refractive elements, diffraction elements, and the like, are stamped (see The Novel Fabrication Method and Optimum Tooling Design Used for Microlens Arrays, Proceedings of the 1st 〇 IEEE International Conference on Production by Nano/Micro Engineered and Molecular Systems ; January 1 8-21, 2006, Zhuhai, China). Embossing refers to first applying a liquid or plastically deformable material i to a substrate and then stamping it with an imprinting mold. [0003] Please refer to Figure 1, when manufacturing a concave lens, or other concave lens: 1 't - : t ? t , for example, a crescent lens or a toric lens, the following method can be used: ip I s '" 〇 provides a transparent substrate 10, according to the optical area of the concave lens 12 to be edged (the area through which the light passes) The surface of the concave lens is formed into a mold core 14, and the mold core 14 includes a molding surface 140 which is exactly opposite to the surface shape of the concave lens 12 and which is an outwardly convex surface. The molding material is coated on the transparent substrate 1' to press the mold core 14 toward the molding material, and since the molding surface 140 protrudes beyond the mold core 14, the molding material is pressed, so that a part of the molding material overflows to the periphery, heat curing or ultraviolet curing. After photocuring, portions of these overflow molding regions cause the area of the non-optical region 120 outside the concave lens surface of the concave lens 12 to be too large, and the thickness is too thick, in the later processing, 098117614 Form No. 1010101 Page 3 of 17 page 0982029921 -0 201041712 Therefore, it is necessary to grind or cut the amorphous portion into a molding material, which is wasteful and increases the production cost. [0004] [0005] [0006] [0007] In particular, when the size of the concave lens is getting smaller and smaller, for example, as small as a micron or a millimeter, the accuracy is required to be higher, and a plurality of fine concave lenses arranged or disordered are produced at one time, since each A plurality of molding materials are overflowed outside the embossed area of the molding surface 140, so that a large amount of molding material is accumulated between the adjacent two concave lenses 12, and the problem that the non-optical area is too large and the thickness is too thick may be caused. The precision of the concave lens is greatly reduced, so it is necessary to minimize the overflow of the molding material and reduce the waste. [Invention] In view of the above, it is necessary to provide a mold, a molding device and a method for embossing a micro concave lens array of a molding material. . A mold for embossing a micro concave lens array having a surface formed with a plurality of spacers, each of the ends of the spacer having a top surface, and a top surface of each spacer is flush with the surface Each of the spacers defines a molding cavity for molding a micro concave lens, and the molding cavity is provided with a convex molding surface, and the convex molding surface is convex outward from the bottom of the molding cavity, and the highest point of the convex molding surface a molding device for embossing a micro concave lens array, comprising a mold core and a substrate for carrying a molding material; the mold core having a surface formed with a plurality of spacers, each of which is formed by a top surface of the spacer The end of the spacer has a top surface, and the top surface of each spacer is flush with the surface, so that the top surface of the spacer can be flushed to the substrate when embossing; each spacer is defined Form No. A0101 Page 4 / Total 17 pages 201041712 A molding cavity for molding a micro concave lens, wherein the molding cavity is provided with a convex molding surface which is convex outward from the bottom of the molding cavity , The highest point of the convex shape of the mold surface below the top surface of the spacer. [0008] A method for embossing a micro concave lens array, comprising the following steps: [0009] providing a substrate having a bearing surface; [0010] coating a molding material on the bearing surface; [0011] providing a mold core, The mold core has a surface formed with a plurality of spacers, each of the spacers has a top surface, the top surface of each spacer is flush with the surface, and each spacer defines a micro concave lens for molding a molding cavity, wherein the molding cavity is provided with a convex molding surface, the convex molding surface is convex outward from a bottom of the molding cavity, and a highest point of the convex molding surface is lower than a top surface of the spacer; [0012 Pressing the mold core against the bearing surface, so that the top surface of the spacer of the mold core directly presses against the bearing surface, thereby obtaining a concave lens preform in each molding cavity of the mold core; [0013] curing the concave lens Preform; [0014] demoulding. [0015] Compared with the prior art, the convex molding surface of the mold core provided by the present invention is respectively disposed in the molding cavity defined by the spacer, so that the molding material can be defined in the molding cavity without being easily pressed to the molding cavity. In addition to the molding cavity, the waste of the molding material is minimized; accordingly, the molding device and method for manufacturing the micro concave lens array by the molding device can also be 0982029921-0 098117614 Form No. A0101 Page 5 of 17 201041712 Reduce the waste of molding materials. [Embodiment] [16] The present invention will be further described in detail below with reference to the accompanying drawings. 2, 3, and 4, the mold core 2 provided by the embodiment of the present invention has a surface 20'. The surface 20 is formed with a plurality of spaced apart spacers 36, and each of the spacers 36 has an end portion thereof. The top surface 360 is flush with the surface 20, and each of the spacers 36 defines a molding cavity 34 for molding a micro concave lens, and each of the molding chambers 34 is provided with a convex molding surface 26. Since the spacer 36 is of a repeating structure, the portion of the mold core where each of the vessels 36 is located can be regarded as a single body of the mold core 2. [0018] The "micro" concave lens refers to a small lens of a small size, typically of the order of micrometers or millimeters. [0019] In this embodiment, the spacer 36 is a ring body or a hollow cylinder, which may also be a "back," font, or other closed curve formed by two inner and outer rectangles. Structure 6 In summary, each of the spacers 3 6 independently defines a molding cavity 34. [0020] The plurality of spacers 36 may be connected in position or may be spaced apart by a distance as long as needed. The plurality of spacers 36 may be arranged in an ordered or disordered manner, correspondingly to obtain a micro concave lens array composed of a plurality of ordered or disordered micro-concave lenses formed at one time. [0021] 098117614 convex molding The surface 26 is outwardly convex from the bottom of the cavity 34, and the convex point of the convex molding surface 26 is lower than the top surface 36. In the embodiment, the vertex 〇 of the convex molding surface 26 is lower than the interval. The top surface of the body % is 36. If the convex form number Α _ 苐 6 pages / a total of 17 pages 0992029921-0 201041712 [0022] Ο [0024] [0024]
GG
[0025] 面形模壓面2 6之頂點Ο超過頂面3 6 0，則無法達到將成型 材料限定模壓腔内之目的。在生產中，頂面36〇超出凸面 形抵廢面2 6之頂點〇之高度需要考慮成型材料之流動性以 及凹透鏡之直徑、厚度等因素。 在本實施例中，一個凸面形模壓面26可對應成型一個凹 透鏡。凸面形模壓面26是一個球凸表面或者非球面凸表 面，以成型球凹透鏡表面或非球面凹透鏡表面。凸面形 模壓面26當然也可以包括多個連續之或者不連續之凸面 ’以此對應成型多個連續之或者不連續之凹透鏡。 在本實施例中’間隔體36具有朝向模壓腔34内部之内侧 面24，該内側面24參與成型凹透鏡之一部分，比如凹透 鏡之侧面等。因此，也可以說内側面24和凸面形模壓面 26構成了成型面22 ’該成型面22用於成型凹透鏡。 在本實施例中，内側面24垂直於表面20，且内側面24之 邊緣和凸面26之邊緣相接。當然，内側面24還可以以其 他方式出現，例如，相對表面2〇傾斜之斜面或曲面等。 只要是用於成型凹透鏡表面之凸面形模壓面26位於模壓 腔34内即可。如有需要，内側面24之邊緣也可以不與凸 面形模壓面2 6之邊緣相接。 在壓印凹透鏡之過程中，成型材料將會因間隔部36之存 在而被限定在模壓腔34内。由於模壓腔34之體積小，所 用成型材料之體積也小，又因為較少有成型材料被擠壓 到模壓腔34之外，因此不會形成面積過大、厚度過厚之 非光學區，也就減少了對成型材料之浪費。 098117614 表單編號Α0101 第7頁/共17頁 0982029921-0 201041712 [0026] [0027] [0028] [0029] [0030] 本發明實施例提供之模絲置包括模仁2和用於承載成型 材料之基板50。基板5G具有-承載面51，該承載面51用 於塗布成型材料。在壓印時，模仁2之間隔體36之頂面 360將抵壓至該承載面51，以形成一個完整之盡可能封閉 之模壓空間。 利用該模壓裝置壓印微小凹透鏡陣列之方法包括以下步 驟： 首先，於該承載面51塗布成型材料；其次，將模仁2壓向 該成型材料，並使得該模仁2芝間隔體36之頂面36〇直接 與該承載面51相抵壓，從而在該模仁2之每個模壓腔以内 獲得凹透鏡預形體；接著，固化該凹透鏡預形體；最後 ，脫模，獲得由多個微小凹透鏡7〇組成乏微小凹透鏡陣 列。 由於模壓腔34之間相互間隔，因此形成之微小凹透鏡7〇 之間也相互間隔。正是由於模壓腔34和間隔部36之存在 ，成型材料被限定在模壓腔34所限定之區域而不太容易 被擠壓到模壓腔34之外，因此可減少對成型材料之浪費 〇 塗布愿印材料時’既可以在承載面51均句塗布一層連續 之成型材料’也可以在承載面51劃定多個相互間隔之預 成型區域’該多個預成型區域與該多個成型區域相對應 ，然後在每個預成型區域塗布該成型材料。 在壓印之過程中，可能會有部分光學材料被壓在間隔部 36之下而形成了連接兩個微小凹透鏡之連接部但是 098117614 表單編號A0101 第8 1/共π頁 0982029921-0 [0031] 201041712 厚度非常薄，這樣之連接部既可以使多個凹透鏡連成一 體也方便後續切割工作。 [0032] 需要注意之是，塗布之成型材料之體積大於所有成型區 域之體積之和，這樣才能充分填充所有成型區域，但這 依然小於現有技術中需要塗布之成型材料之體積。因為 I現有技術中’成型面140之間無阻隔，為了提高壓印品 質’成完全填充’所以成型材料之 體積要大很多。 〇 [酬在本實施例中，由於承載面51為平面，所以形成之微小 凹透鏡70是平！透鏡。但是，也可以是其他具有凹面之 光學透鏡，例如新月形透鏡或者複曲面透鏡等。 [0034] 圖 【圖式簡單說明】 1是利用習知技術提供之模仁製造凹透鏡陣列之示意 圖 [0035] Ο 圖2是利用本發明實施例提供之模仁製造微小 之刻視圖。 凹透鏡陣列 [0036] [0037] [0038] 098117614 圖3是本發明實施例提供之模仁之單體之剖視圖。 圖4是本發明實施例提供之模仁之單體之仰視圖。 【主要元件符號說明】[0025] When the apex of the surface molding surface 26 exceeds the top surface 360, the purpose of defining the molding material in the molding cavity cannot be achieved. In production, the height of the top surface 36〇 beyond the apex of the convex-shaped offset surface 6 6 needs to take into account the fluidity of the molding material and the diameter and thickness of the concave lens. In the present embodiment, a convex molding surface 26 can be formed correspondingly to a concave lens. The convex molding surface 26 is a spherical convex surface or an aspherical convex surface to form a spherical concave lens surface or an aspherical concave lens surface. The convex shaped embossed surface 26 may of course also comprise a plurality of continuous or discontinuous convex surfaces' to correspondingly shape a plurality of continuous or discontinuous concave lenses. In the present embodiment, the spacer 36 has an inner side surface 24 facing the inside of the molding cavity 34, and the inner side surface 24 participates in forming a portion of the concave lens, such as the side of the concave lens. Therefore, it can also be said that the inner side surface 24 and the convex surface molding surface 26 constitute a molding surface 22' which is used for molding a concave lens. In the present embodiment, the inner side 24 is perpendicular to the surface 20 and the edges of the inner side 24 are in contact with the edges of the convex surface 26. Of course, the inner side 24 can also be present in other ways, such as a beveled surface or curved surface that is opposite the surface 2〇. As long as the convex molding surface 26 for molding the surface of the concave lens is located in the molding cavity 34. The edge of the inner side surface 24 may also not be in contact with the edge of the convex molding surface 26 if desired. During the embossing of the concave lens, the molding material will be confined within the molding cavity 34 due to the presence of the spacers 36. Since the volume of the molding cavity 34 is small, the volume of the molding material used is also small, and since less molding material is extruded outside the molding cavity 34, a non-optical zone having an excessively large area and an excessively thick thickness is not formed. Reduced waste of molding materials. 098117614 Form No. 1010101 Page 7 of 17 0982029921-0 201041712 [0030] [0030] [0030] The die set provided by the embodiment of the present invention includes a mold core 2 and a material for carrying the molding material. Substrate 50. The substrate 5G has a bearing surface 51 for coating a molding material. At the time of imprinting, the top surface 360 of the spacer 36 of the mold core 2 will be pressed against the bearing surface 51 to form a complete molded space that is as closed as possible. The method for imprinting a micro concave lens array by using the molding device comprises the steps of: first, coating a molding material on the bearing surface 51; secondly, pressing the mold core 2 against the molding material, and making the top of the mold core 2 the spacer 36 The face 36〇 is directly pressed against the bearing surface 51 to obtain a concave lens preform within each of the molding cavities of the mold core 2; then, the concave lens preform is cured; finally, the mold is released, and a plurality of micro concave lenses are obtained. A microscopic concave lens array is formed. Since the molding cavities 34 are spaced apart from each other, the formed micro concave lenses 7 are also spaced apart from each other. Due to the presence of the molding cavity 34 and the spacer 36, the molding material is limited to the area defined by the molding cavity 34 and is less likely to be extruded outside the molding cavity 34, thereby reducing waste of the molding material. When printing the material, it is possible to apply a continuous molding material on the bearing surface 51 or to define a plurality of mutually spaced pre-formed regions on the bearing surface 51. The plurality of preforming regions correspond to the plurality of molding regions. The molding material is then applied to each of the preformed regions. During the imprinting process, some of the optical material may be pressed under the spacer 36 to form a connection connecting the two micro concave lenses but 098117614 Form No. A0101 No. 8 1 / Total π page 0992029921-0 [0031] 201041712 The thickness is very thin, so that the joint can make a plurality of concave lenses integrated and facilitate subsequent cutting work. [0032] It should be noted that the volume of the coated molding material is larger than the sum of the volumes of all the molding regions, so that all the molding regions can be sufficiently filled, but this is still smaller than the volume of the molding material that needs to be coated in the prior art. Since there is no barrier between the molding faces 140 in the prior art, the volume of the molding material is much larger in order to improve the imprint quality to be completely filled. 〇 [In this embodiment, since the bearing surface 51 is a flat surface, the formed micro concave lens 70 is flat! lens. However, it may be another concave optical lens such as a crescent lens or a toric lens. BRIEF DESCRIPTION OF THE DRAWINGS [Fig. 1 is a schematic view showing the manufacture of a concave lens array by a mold provided by a conventional technique. [0035] Fig. 2 is a view showing the manufacture of a mold core according to an embodiment of the present invention. Concave Lens Array [0038] FIG. 3 is a cross-sectional view of a monomer of a mold core according to an embodiment of the present invention. 4 is a bottom plan view of a single of the mold core provided by the embodiment of the present invention. [Main component symbol description]
第9頁/共Π頁 0982029921-0 透明基板 凹透鏡 模仁 非光學區 成型面 表單編號A0101 201041712 模仁 2 端面 20 内側面 24 凸面形模壓面 26 模壓腔 34 間隔體 36 基板 50 承載面 51 微小凹透鏡 70 頂面 360 成型面 Ο 〇 L· L· 098117614 表單編號A0101 第10頁/共17頁 0982029921-0Page 9/Total page 0992029921-0 Transparent substrate concave lens mold non-optical area molding surface Form No. A0101 201041712 Mould 2 End face 20 Inner side 24 Convex molding surface 26 Molding cavity 34 Spacer 36 Substrate 50 Bearing surface 51 Micro concave lens 70 Top 360 Forming Face 〇L· L· 098117614 Form No. A0101 Page 10 of 17 0982029921-0