JP3143573B2 - Optical element molding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding an optical element such as a glass lens or a prism by press molding.

[0002]

2. Description of the Related Art An oil / pneumatic cylinder has been mainly used as a drive source of a conventional general optical element press forming apparatus. However, since there are problems such as noise and dirt generated from the driving source, stability of the shape and accuracy of the molded product, and poor reproducibility, a servo motor is currently receiving attention as a driving source.

However, even if a servomotor is used, position control and torque control cannot be performed simultaneously. This means that if a low-viscosity material is controlled and pushed at the position, the position will move when trying to reach the set torque, or conversely, it will be controlled with the torque and moved to the set position. If so, the torque fluctuates. It is clear from this. Further, even if the torque control is performed, when the set position is reached, there is a problem that the position is prioritized and the process proceeds to the next program.

[0004]

SUMMARY OF THE INVENTION In a molding apparatus using a servomotor as a drive source, a glass material is arranged between a pair of upper and lower molds, and the mold and the glass material are heated to press-mold an optical element. In the case where the glass material is pressed without bringing the upper and lower molds to the final contact position and then cooled to press-mold the optical element, position control and torque control cannot be performed simultaneously.

For this reason, if position control is performed to a set position where the upper and lower dies do not reach the final close contact position, the process immediately shifts to the next program after reaching the set position. Even if it is held, if the press shaft to which the mold is connected shrinks in the cooling step, the position is held because the position is controlled, but it cannot follow the change in temperature, so that it adheres to the glass material. The state cannot be maintained.

That is, the pressing force applied to the glass material fluctuates, and a gap is formed between the upper and lower molds by the contraction amount of the press shaft. Since the glass material is not held by the upper and lower molds, the glass material in the gap is Moves, the result is that the glass material is pressed in a "displaced" state when the final press is performed, and there is a problem that a good product cannot be obtained.

Next, when the control of the moving mold is performed by the torque control, as described above, even if the control is performed by the torque control, when the set position is reached, the position is prioritized and the program shifts to the next program.

As a solution to this problem, if the set position is set to a position (virtual close contact position) higher than the actual mold contact position and it is impossible to reach the set position indefinitely, the temperature will change. Follow. However, since the pressing force cannot be controlled because the torque is pushed down to the set torque value, when the viscosity of the glass material is low, the mold moves to the final contact position because there is no resistance when the glass material has a low viscosity. There is a problem that the thickness of the film cannot be controlled.

As described above, in the press forming apparatus for an optical element using a servo motor as a drive source, the glass material is pressed without the upper and lower dies reaching the final contact position, and then cooled to form the optical element. In such a case, it was impossible to keep the thickness of the glass during forming unchanged and to keep the glass from separating from the mold. That is, it was not possible to obtain a press-formed product (optical element) having reproducibility in the thickness of the formed product and high accuracy.

The present invention has been made based on the above circumstances, and an object of the present invention is to provide a molding method of an optical element capable of obtaining a highly accurate optical element having reproducibility of thickness.

[0011]

According to the present invention, as a means for solving the above-mentioned problems, a glass material is arranged between a pair of upper and lower molds, and the mold and the glass material are heated to press the optical element. A forming method for forming, using a servomotor as a drive source of the press shaft, performing a press as a linear motion thrust of the press shaft through a transmission mechanism such as a worm jack, and using a position detector. A position control step of controlling the position of the movable mold attached to the press shaft, and a load detector for detecting a press force as an actual load, and a difference between the press force and a preset press force. A torque feedback step of controlling the current value to be applied to the servomotor in a closed loop by means of a closed loop. In press molding, the upper and lower dies are located at a set position slightly before the final mold closed state. By moving the mold by control to reach the set position, immediately after reaching the set position, switch to torque control of a small force so that the glass material is not deformed, do not deform the thickness of the glass being formed, In addition, the process proceeds to a cooling step while maintaining a state where the glass and the mold do not separate from each other, and after reaching a set temperature or holding for a set time, the glass material is subjected to final pressing with a deformable pressing force. . It is desirable that the set temperature at which the final pressing is performed is around the glass transition point (Tg).

[0012]

According to the optical element molding method of the above means, the upper and lower molds are closed after the molds are heated to heat the glass material disposed between the molds to a temperature between the transition point and the softening point. The mold (axis) is moved to a set position slightly before the state by position control to reach the set position. At this time,
Since the movement of the mold (axis) is controlled by the servo motor,
Accurate and reproducible. Immediately after reaching the set position, the glass material is switched to torque control with a small force so that the glass material is not deformed, and the torque feedback control is performed. In addition, since the state in which the mold and the glass are in close contact with each other can be maintained, a high-precision optical element having reproducibility of thickness and high precision can be obtained.

When the temperature of the glass material is close to the glass transition point (Tg), the final press is performed to improve the transferability between the mold and the glass material, and to improve the precision of the formed optical element. It can be further improved.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIG. A fixed shaft 2 extends downward from an upper portion of the frame 1, and an upper die assembly 4 is attached to a lower end of the fixed shaft 2 via a ceramic heat insulating cylinder 3 by bolts or the like (not shown).

The upper die assembly 4 includes a metal die plate 5,
An upper die 6 made of ceramic, cemented carbide or the like, and a fixed die 7 for attaching the upper die 6 to the die plate 5 and forming a part of the die.

A servo motor 8a is provided below the frame 1.
A driving device 8 such as a screw jack for converting the rotational motion of the servo motor 8a into a linear motion thrust is provided, and a moving shaft 9 as a press shaft is attached to the driving device 8 via a load detector 8b. Have been.

The moving shaft 9 moves up and down so that speed, position and torque can be controlled by a program input to the control device 28, and extends upward facing the fixed shaft 2. At the upper end of the moving shaft 9, a heat insulating cylinder 10 similar to the heat insulating cylinder 3 is provided.
The lower die assembly 11 is attached via bolts and the like (not shown).

The lower die assembly 11 includes a die plate 12, a lower die 13, and a moving die 14. A bracket 15 that is moved up and down by a driving device (not shown) is movably fitted to the fixed shaft 2. A transparent quartz tube 16 surrounding the upper mold assembly 4 and the lower mold assembly 11 forming a pair is attached to the bracket 15.

The lower end of the transparent quartz tube 16 is in airtight contact with the intermediate plate 1a through which the moving shaft 9 passes, and the molding chamber 1 is closed around the upper mold assembly 4 and the lower mold assembly 11 from the atmosphere.
7 are formed.

The transparent quartz tube 1 is mounted on the bracket 15.
An outer cylinder 18 surrounding the tube 6 is attached, and a lamp unit 19 is attached to the outer cylinder 18. Lamp unit 1
Reference numeral 9 denotes an infrared lamp, a reflection mirror 21 disposed behind the infrared lamp 20, and a water cooling pipe 22 for cooling the reflection mirror 21 and the like. The upper die assembly 4 and the lower die assembly 11 are heated. Has become.

The fixed shaft 2, the moving shaft 9, and the bracket 15 are provided with an inert gas atmosphere in the molding chamber 17,
Gas supply paths 23, 24, and 25 for cooling the upper mold assembly 4 and the lower mold assembly 11 are provided, and an inert gas is supplied to the molding chamber 17 at a predetermined flow rate via a flow controller (not shown). ing. The inert gas supplied to the molding chamber 17 is exhausted from the exhaust port 26. Reference numeral 27 denotes a thermocouple for detecting the temperature of the lower die assembly 11.

Next, a method of molding an optical element according to the present invention using the molding apparatus will be specifically described with reference to FIG. 2 showing a program incorporated in the control unit 28 and a molding profile at that time.

The bracket 15 is raised along the fixed shaft 2, the molding chamber 17 is opened, and the glass material 30 is carried onto the lower mold 13. The glass material 30 used was a sphere having a glass type of BK-7 (transition point = 557 ° C., softening point = 719 ° C.) and a shape having an outer diameter of 9 mm.

Next, the bracket 15 is lowered, the molding chamber 17 is closed by the transparent quartz tube 16, and the gas supply path 2 is closed.
An inert gas is supplied from 3, 24, 25 to make the inside of the molding chamber 17 an inert gas atmosphere. The supply time of the inert gas is set from the control unit 28, and is set to 10 seconds in consideration of the volume in the molding chamber 17 and the supply flow rate.

When the supply time expires, the command G01Z24.000F500 of 100 lines in the example of the program shown in FIG. 2 is executed. Here, G01 is a linear interpolation code (position control code) in an ordinary NC device, and the moving shaft 9 moves at a speed of F to a position of Z. Note that Z is the absolute amount (mm) from the origin, and F is the moving speed (mm / min).

That is, in response to a command of 100 lines, the moving axis 9 moves from the origin to a position 24.000 mm upward at a speed of 5 mm.
It rises at a speed of 00 mm / min. The amount of movement of the moving shaft 9 is counted by an encoder (not shown) incorporated in the servomotor 8a, and the position where the glass material 30 and the upper die 6 have a small gap confirmed in advance (= 24.
000 mm) by position control.

Normally, when the position control is performed, the program shifts to the next program in response to a signal reaching the set position. However, since the position is a preheating position for heating the glass material 30 to a pressable temperature, a soak time to be described later is used. Until the time is up, the control unit 2
8 is set.

Next, the upper mold assembly 4, the lower mold assembly 11 and the glass material 30 are heated by the lamp unit 19 through the transparent quartz tube 16. The upper mold assembly 4, the lower mold assembly 11, and the heating of the glass material 30 are controlled by controlling the output of the thermocouple 27 for temperature detection and the output of the infrared lamp 20 based on the output by the control unit 28. 705
° C.

Since the temperature of the glass material 30 cannot be directly measured and is replaced by the temperature of the lower die assembly 11, a certain time (Soak Time) is set until the temperature of the glass material 30 reaches 705 ° C. It is desirable to keep. Considering the material and heat capacity of the mold, this time
k Time = 120 seconds.

When the time of the Soak Time is up, the command G01Z30.000F20 on the 110th line of the program is executed. Note that the position was set to 30.000 mm 0.5 mm below the upper and lower molds because the contact position of the upper and lower molds was 30.500 mm when heated to 705 ° C.

The drive unit 8 is driven by the control unit 28, and the moving shaft 9 is controlled by the position control at a moving speed of 20 mm / min until the upper and lower dies reach a position of 30.000 mm 0.5 mm below the final mold closed state. Raised. As a result, the glass material 30 is pressed by the upper and lower dies 6 and 13 and molded. The thickness of the glass material 30 after pressing is expected to be 3.026 mm as a result of calculation from the gaps between the upper and lower dies 6 and 13.

Upon reaching the set position, the command G200Z40.000F20I10E1V1 for the 120th line of torque control is immediately executed.

Here, the G200 code will be described. The G200 code is a torque control code developed for an optical element molding apparatus. The G200 code moves the moving axis at a speed of F (mm / min) to a position of a set Z (amount of assemblage from the origin; mm). Although this is a command for performing torque control with a pressing force of (kgf), it is possible to perform torque feedback control so as to maintain the set pressing force.

Specifically, by writing the E1 code in the program, the actual pressing force can be detected by the load detector 8b.
, And the output is taken into the control unit 28 as a feedback signal so that the set pressing force is maintained.
The current value applied to the servo motor 8a as a drive source is controlled in a closed loop. Further, the program can be shifted to the next program by reaching the set position or by the forced stepping code V.

Now, even if the torque control command is given, when the set position is reached, the position takes precedence, and the program moves on to the next program. A position (virtual close contact position) further higher than the position is set to 40.000 mm, and the process is shifted to the next program by the forced stepping code V1.

That is, until the forced stepping code V1 is output, the glass material 30 being formed is not deformed.
Since the pressing force set in advance is 10 kgf and is maintained by the torque feedback control, the thickness of the glass material 30 during forming does not change.

Next, the infrared lamp 20 is turned off and the cooling process is started. During this time, the torque feedback control is performed with a pressing force of 10 kgf so that the glass material 30 is not deformed. The moving shaft 9 moves so as to absorb the contraction amount, and the moving amount is equal to the contraction amount of the shaft.
The gap between 13 does not change.

That is, the thickness of the glass material 30 being formed does not change, and the glass material 30
Since the pressing force of 0 kgf is applied and the upper and lower dies 6 and 13 are in contact with each other, the pressing force applied to the glass material 30 and the uniform cooling of the inside of the glass can be achieved. Further, since the glass material 30 does not move, a final press described later is not performed in a state where the glass material 30 is “displaced”.

Next, when the temperature reaches 565 ° C., which is slightly higher than the preset transition point, the forced stepping code V1 is output, and the command G200Z40.000F20I100E1V2 in the 130th line of the program is executed. Since this command is for performing the final press and is the same torque feedback control as in the above-mentioned 120th line, the transfer surface of the mold is pressed again against the glass material 30 with the set press force of 100 kgf, so that the transferability thereof is more reliable. It can be something.

Since the movement axis 9 was confirmed to rise by 2 μm in this step, the thickness of the resulting optical element is expected to be 3.024 mm. This operation is performed until the temperature of the glass material 30 reaches 557 ° C. (= glass transition point).

When the temperature reaches 557 ° C. and the forced stepping code V2 is output, the program 140 line G200Z40.000F20I50E1V3 is executed, and the control is switched to the torque feedback control at the set pressing force of 50 kgf.

This step is provided to maintain the contact between the upper and lower dies 6, 13 and the glass material 30, and to equalize the pressing force applied to the glass material 30 and the cooling inside the glass. Since the temperature is lower than the transition point, the shape of the glass material 30 does not change.

When the set temperature reaches 220 ° C.,
The program G01Z0.000F500 of 150 lines is executed by the forced stepping code V3, and the moving axis 9 moves to the origin at a moving speed of 500 mm /
min, the mold is opened, and the molding is completed.

Press molding was performed 35 times with the above-described molding profile. The expected optical element thickness is 3.024 mm. Regarding the surface accuracy, since the surface accuracy of both the upper and lower dies 6 and 13 was about λ / 10 (λ = about 633 nm), the transferability was determined based on this value.

Each of the resulting optical elements has a thickness of 3.024 mm ± 1 μm and a surface accuracy of about λ / 1.
0, indicating that a highly accurate optical element having the expected thickness was obtained.

As another example of a program, switching between 120 lines and 130 lines of the program (press force of 10 kg)
f and 100 kgf) by Soak Ti
A certain time may be set on the basis of the time-up of me, and may be performed after the elapse of the set time. In the above-described embodiment, the infrared lamp 20 is used as the heating source. May be used, and the load detector 8b may be provided not only between the driving device 8 and the moving shaft 9 but also between the servo motor 8a and the lower mold 12. Furthermore, it is a matter of course that various changes can be made in the cooling step of the glass material 30, such as providing a slow cooling section.

[0047]

As described above, according to the present invention, after the glass material is heated to a temperature between the transition point and the softening point, the upper and lower dies are set to the set positions slightly before the final mold is closed.
The shaft (die) is moved by position control to reach a set position. At this time, since the movement of the shaft (die) is controlled by the servomotor, it can be performed accurately and with good reproducibility.

Immediately after reaching the set position, the control is switched to the torque control, and the torque feedback control is performed with a small force so that the glass material is not deformed.
Enables simultaneous position control and torque control,
Even after moving to the cooling step, the thickness of the glass being formed is not changed, and the mold and the glass can be kept in close contact.As a result, the thickness is reproducible, and A highly accurate optical element can be obtained.

When the temperature of the glass material is close to Tg, the final press is performed to improve the transferability between the mold and the glass material, and to further improve the precision of the formed optical element. Can be.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view showing a specific example of an optical element molding apparatus for implementing the present invention.

FIG. 2 is a diagram showing an example of a program for realizing the present invention and an example of a molding profile.

[Explanation of symbols]

2: fixed shaft, 4: upper die assembly, 5: die plate, 6: upper die, 7: fixed die, 8: driving device, 8a: servo motor, 8b: load detector, 9: moving shaft, 11: lower Mold assembly,
12: die plate, 13: lower die, 14: moving die, 1
5 bracket, 16 transparent quartz tube, 17 molding chamber, 1
9 lamp unit, 20 infrared lamp, 23, 2
4, 25: gas supply path, 27: thermocouple for temperature detection, 28
... Control unit.

──────────────────────────────────────────────────続 き Continued on the front page (72) Isao Matsuzuki, Inventor 2068-3 Ooka, Numazu-shi, Shizuoka Toshiba Machine Co., Ltd. Numazu Office (72) Inventor Hirotaka Masaki 2068-3, Ooka, Numazu-shi, Shizuoka Toshiba Machine Co., Ltd. (58) Field surveyed (Int. Cl. ⁷ , DB name) C03B 11/16 C03B 11/00

Claims (2)

(57) [Claims] 1. A glass material is arranged between a pair of upper and lower molds,
A molding method for press-molding an optical element by heating the mold and the glass material, wherein a servomotor is used as a drive source of the press shaft, and the torque is transmitted to a linear motion of the press shaft via a transmission mechanism such as a worm jack. A step of pressing as a thrust, a position control step of controlling the position of a moving mold attached to the press shaft using a position detector, and a pressing force, which is an actual load, is detected by a load detector,
A torque feedback step of controlling the current value applied to the servomotor in a closed loop based on a difference between the press force and a preset press force. The mold is moved to a set position slightly before by the position control so as to reach the set position, and after reaching the set position, the torque is switched to torque control with a small force so that the glass material is not deformed. Move to the cooling step while maintaining the state that the glass and the mold do not separate from each other without deforming the thickness of the glass.After reaching the set temperature or holding for the set time, the glass material is finally pressed with a deformable pressing force. A molding method for an optical element. 2. The method of molding an optical element according to claim 1, wherein the set temperature to reach the final pressing is near the glass transition point (Tg).