JP4033635B2

JP4033635B2 - Composite optical component and manufacturing method thereof

Info

Publication number: JP4033635B2
Application number: JP2001011978A
Authority: JP
Inventors: 秀信岸; 俊宏金松; 克之大窪
Original assignee: Ricoh Co Ltd
Current assignee: Ricoh Co Ltd
Priority date: 2001-01-19
Filing date: 2001-01-19
Publication date: 2008-01-16
Anticipated expiration: 2021-01-19
Also published as: JP2002210771A

Description

【０００１】
【産業上の利用分野】
この発明は、光学機能素子と補強部材とを複合して、光学機能素子の変形を防止して変形による光学機能素子の所期の機能低下を防止する複合光学部品及びその製造方法に関するもので、温度変化による光学機能素子と補強部材間の熱膨張差による光学機能素子の熱歪みを低減するとともに、光学機能素子の真直度を高め、かつ、複合部品の製造コストを低減することができるものであって、真直度及び高強度が求められる種々の高性能複合光学部品に適用することができるものである。
【０００２】
【従来の技術】
この発明の前提技術となるものではないが、技術的に関連すると思われる従来の技術として、特開平８−２８１７６３号公報に記載された「複合長尺材及びその製造方法」がある。このものは、被曲げ部を有する複合長尺部の接合部に潤滑面を有する係合部を設け、変形を抑えるものであるが、潤滑部の摩耗粉等の異物の逃げ場がないので、摺動部に異物が介入して複合部材が固着乃至は摺動抵抗が大きくなって摺動時の変形による歪みが発生する恐れがある。
また、他に特開平７−１９５４３５号公報に記載された「技術的デバイス及び機能部分射出成形方法」がある。このものは、軸受部分の機能を確保するために、アウトサート部分の結合部にプラスチックフィルムを介在させ、かつ、成形後の収縮差により表面から分離させるものであるが、フィルム等を介在させることによりコスト高になり、また樹脂の収縮により結合部との隙間が大きく、ガタツキが発生するため高精度な位置決めが必要な複合機能部品には適さず、また、被曲げ部を有する複合長尺部の接合部に潤滑面を有する係合部を設け、変形を抑える方法を採っているが、潤滑部の摩耗粉等の異物の逃げ場がないため、摺動部に異物が介入して複合部材が固着される恐れがあり、さらに、軸受部分の機能を確保するためにアウトサート部分の結合部にプラスチックフィルムを介在させ、かつ、成形後の収縮差により表面から分離させるものであるが、フィルム等を介在させるものであるからコスト高になることは避けられない。
【０００３】
他方、高精度が求められるレンズアレー等の複合光学機能部品においては、部分的な面精度の外にその所要の真直度を確保することが大きな課題となる。特に長尺形状であるほど真直度確保が難しい。
上記の複合光学機能部品においては、部分的な面精度の外に所要の真直度を確保するために、これを射出成形によるアウトサート成形することが知られているが、コスト低減のために、これを高精度が求められるレンズアレー等の複合光学機能部品に適用すると、樹脂がアウトサートされた補強部材に密着しやすく、成形後の収縮時及びその使用環境での熱膨張により光学機能素子（レンズ等）に熱歪みを生じ、あるいは、射出成形時の樹脂圧力による補強部材の一時的な変形がその弾性力によって成形後に復元するため、光学機能素子の高い真直度及び高い面精度を維持することが困難である。
【０００４】
【比較対象技術】
長尺レンズアレー（光学機能素子）と補強部材（保持部材）とを組み合わせた複合長尺光学部品を図１に示している。これは、本発明とは別個の発明であって、公知技術ではないがこの発明の比較対象になるものであるから、この比較対象技術の概略を説明する。
プラスチック製の長尺レンズアレー（機能素子）１０の左右にリブ１０ａを設け、このリブ１０ａの表裏両面に突起１０ｂを設けてあり、他方、アルミ押出成形品である保持部材１１の左右に断面コ形の保持部１１ａを有している。
長尺レンズアレー（機能素子）の左右のリブ１０ａを保持部材１１の保持部１１ａに嵌め込んで滑合（安定的に保持するとともに所定の力に対しては摺動可能な程度の強さで結合された状態の嵌合固定）させて、長尺レンズアレー１０を保持部材１１に組み込んで複合化して、長尺レンズアレー１０を保持部材１１で補強している。
この比較対象技術における複合光学部品の制作手順は次のとおりである。
１）仕様に対して十分な成形精度を備えた長尺レンズアレー（光学機能素子）１０を成形する。
複合部品の機能部の長手方向真直度：仕様３０μｍ以下
成形品の機能部の実測真直度：１７μｍ。
２）光学機能素子と接触する面において高真直度を有する保持部材１１を成形する。
ここではアルミ押出加工品を切削加工して高真直度のものにしている。
長手方向真直度：保持部材測定値１３μｍ。
３）光学機能素子を保持部材に挿入し、基準出しのため接触面を一点で接着して固定する。
複合光学素子の機能部の真直度：２７μｍ。
これにより固定点以外の光学機能素子と保持部材との接触面（突起１０ｂと保持部１１ａの接触面）は摺動可能に、しかしガタがない状態で滑合されるため、長尺レンズアレー（光学機能素子）１０と保持部材１１の熱膨張差にかかわらず長尺レンズアレー（光学機能素子）に歪みが生じることはなく、当該歪みによる長尺レンズアレーの光学性能低下は防止される。
【０００５】
この比較対象技術の場合、長尺レンズアレー１０の成形品単独のときよりも複合部品の素子機能部（複合部品における長尺レンズアレー１０の光学機能部）の真直度が若干低下するので、長尺レンズアレー１０の成形品自体に求められる真直度が複合部品の真直度仕様よりも厳しくなるので、長尺レンズアレー１０の成形コストが高く、また、保持部材自体に高い真直度が求められるので、保持部材の加工コストがかさみ、さらに、光学機能素子と保持部材との組付工程に手間がかかり、複合作業コストが高くなり、その結果、複合長尺光学部品の製造コストが高くなることが避けられない。
【０００６】
【解決しようとする課題】
そこでこの発明は、複合光学機能部品について、熱歪み、補強部材の弾性変形の復元等による光学機能素子の歪みを防止して、高真直度及び高面精度を確保しつつ、製造コストを低減できるように、その構造及び製造方法を工夫することをその課題とするものである。
【０００７】
【課題を解決するために講じた手段】
【複合光学部品についての課題解決手段】
上記課題を解決するために複合光学部品について講じた手段は、光学機能素子と該光学機能素子を保持する保持部材から構成されている複合光学部品を前提として、上記光学機能素子と保持部材とが成形金型内での一体化加工により滑合されていることである。
【０００８】
【作用】
上記光学機能素子と保持部材とが成形金型内での一体化加工により滑合されているから、光学機能素子は保持部材に対して遊びのない状態でしっかりと保持されるが、他方、両者は保持部によってその全長にわたって一体的に固着されているわけではないので、使用中の温度変化によって、光学機能素子が熱膨張して保持部材に対して伸張しようとするときは、保持部による保持力に抗して光学機能素子が保持部材に対して摺動して、熱膨張による光学機能素子の内部歪みが逃がされるから、温度変化時に内部歪みによって光学性能が低下することはない。
また、光学機能素子と保持部材とは、保持部材をアウトサートして、成形金型内で一体化加工されたものであるから、精密加工された光学機能素子と保持部材とを滑合させて複合化する場合（上記比較対象技術など）のように、組合せ誤差などによる光学機能素子の歪み、変形が生じて、光学性能が低下することはないから、複合光学部品は高真直度の光学機能素子を備えたものになり、その性能の信頼度は極めて高い。
【０００９】
【実施態様１】
（請求項１に対応）
実施態様１は、上記解決手段の複合光学部品について、上記光学機能素子と保持部材の上記滑合部における接触面の一点を互いに固定し、残りの接触面を摺動可能にして該光学機能素子に内部歪みを発生させないことである。
【作用】
光学機能素子と保持部材との滑合部における接触面の一点を互いに固定し、残りの接触面を摺動可能にしたことで、光学機能素子全体が保持部材に対して移動して位置ズレを生じることがなく、また、光学機能素子が保持部材に対して基準となる位置で固定されるので、光学複合部品は設計どおりの高性能を発揮することができる。
【００１０】
【実施態様２】
（請求項２に対応）
実施態様２は、上記実施態様１の複合光学部品について、上記光学機能素子と保持部材を凹凸形状の組み合わせ又は接着により互いに固定したことである。
【作用】
光学機能素子と保持部材との上記固定を、簡単容易にかつ確実に行うことができる。
【００１１】
【実施態様３】
（請求項３に対応）
実施態様３は、上記実施態様１または実施態様２の複合光学部品について、上記保持部材又は光学機能素子の一部に溝を設け、複合された状態で光学機能素子又は保持部材に設けられた突起を上記溝に摺動可能に嵌め込んで係合させたことである。
【作用】
熱膨張時の光学機能素子の保持部材に対する伸張方向が、上記溝と突起との係合により光学機能素子の許容方向に規定されるので、熱膨張による光学素子の上記伸張により光学性能が阻害されることはない。
【００１２】
【実施態様４】
実施態様４は、上記解決手段、実施態様１乃至実施態様３の複合光学部品について、上記光学機能素子と保持部材の滑合部の長手方向の摺動抵抗を、光学機能素子の長さ方向の１ｍｍ当たり、ΔＦ＝ａ×Ｓ×Ｅ以内にしたことである。
ただし、
ａ：光学系における熱膨張による光学機能素子の伸び量の許容値（保持部材と光学機能素子の単位長さ当たりの熱膨張の差）
Ｓ：光学機能素子の機能部の断面積
Ｅ：光学機能素子の材料の弾性率（縦弾性係数）
【作用】
上記摺動抵抗を上記ΔＦ以内にしたことにより、光学機能素子の保持部材に対する熱膨張差による光学機能素子の許容限度を越える内部歪みが逃がされるので、光学機能素子と保持部材との熱膨張差による光学機能素子の内部歪みが、その光学機能が損なわれない範囲内に確実に抑制される。
【００１３】
【実施態様５】
（請求項５に対応）
実施態様５は、上記実施態様１乃至実施態様３のいずれかの複合光学部品について、上記光学機能素子の保持部材と接触する部分が樹脂材料であることである。
【作用】
光学機能素子の保持部材との接触部分が樹脂材料であるから、保持部材の保持部とのなじみがよく、したがって、光学素子全体がしっかりと保持部に保持され、また、保持部に対する摩擦抵抗を所定の値以内にコントロールすることが比較的容易である。
【００１４】
【実施態様６】
（請求項６に対応）
実施態様６は、上記実施態様１乃至実施態様３、及び実施態様５のいずれかの複合光学部品について、上記保持部材が金属材料であることである。
【作用】
保持部材（補強部材）は金属材料であるから、光学機能素子に対する補強効果が高く、形状が安定した複合光学部品が得られる。
【００１５】
【実施態様７】
（請求項７に対応）
実施態様７は上記実施態様６の複合光学部品について、その保持部材をアルミの押出成形品、または押出成形品をプレス加工したものにしたことである。
【作用】
アルミ製であるから保持部材（補強部材）は軽量でかつ成形性がよく、したがって、高精度で軽量の複合光学部品を得ることができる。
【００１６】
【実施態様８】
（請求項８に対応）
実施態様８は、実施態様６の複合光学部品について、その保持部材を板金のプレス加工品としたことである。
【作用】
保持部材は板金をプレス加工したものであるから、その成形精度が高く、したがって、高品質の複合光学部品が安定的に得られる。
【００１７】
【実施態様９】
（請求項９に対応）
実施態様９は、実施態様１乃至実施態様３、及び実施態様５のいずれかの複合光学部品について、その保持部材をガラス繊維で強化された樹脂材料製にしたことである。
【作用】
保持部材がガラス繊維で強化された樹脂材料製であるから、保持部材は低コストで高強度のものであり、したがって、低コストで高強度の複合光学部品が得られる。
【００１８】
【実施態様１０】
（請求項１０に対応）
実施態様１０は、実施態様１乃至実施態様３、及び実施態様５乃至実施態様９のいずれかの複合光学部品について、その光学機能素子の機能部が樹脂材料製であることである。
【作用】
光学機能素子の機能部が樹脂製であるから、光学機能素子の予備成形品と保持部材（補強部材）とを複合化加工するときに機能面を転写加工することができるので、機能面の成形加工が容易でかつ高精度に成形され、したがって、機能面が高精度の複合光学部品が低コストで得られる。
【００１９】
【複合光学部品の製造方法についての解決手段】
（請求項１１に対応）
上記課題を解決するために、複合光学部品の製造方法について講じた手段は、光学機能素子と保持部材の接触面の一点を互いに固定し、残りの接触面を固定しないように、成形金型によって複合化される複合光学部品の製造方法について、上記光学機能素子に対する金型駒の光学機能面の転写と、上記光学機能素子と保持部材の接触面における一点での固定とを同一成形過程で行うことである。
【作用】
光学機能素子と保持部材とを向き合わせた状態で成形金型に装着して、光学機能素子と保持部材の接触面の一点を互いに固定し、残りの接触面を固定しないように複合化するときに、光学機能素子の光学機能面を転写加工するものであるから、光学機能素子の予備成形品及び低真直度の保持部材を用いることができ、かつ、複合化の時に光学機能面が転写加工されるから、当該機能面が複合化工程で歪みを生じることはなく、したがって、低コストで、極めて高精度の光学機能面を備えた複合光学部品を能率的に製造することができる。
【００２０】
【実施態様１】
実施態様１は、上記解決手段の製造方法について、上記光学機能素子に対する金型駒の光学機能面の転写と、光学機能素子と保持部材の滑合とを、同一成形過程において別機構を用いて行うようにしたことである。
【作用】
上記光学機能素子に対する金型駒の光学機能面の転写と、光学機能素子と保持部材の滑合とを、同一成形過程において別機構を用いて行うことで、保持部材と光学機能素子との滑合部に、所定の固定保持力を備えた滑合面を確実に形成することができるので、高精度で高真度の複合光学部品を能率的に製造することができる。
【００２１】
【実施態様２】
（請求項１２に対応）
実施態様２は、上記解決手段による製造方法について、その保持部材に予備成形品を挿入した後、金型駒の光学機能面を転写することである。
【実施態様３】
（請求項１３に対応）
実施態様３は、上記実施態様２の製造方法について、上記予備成形品が樹脂材料であり、光学機能面を有する金型駒を移動させて樹脂を加圧することで金型駒の光学機能面を転写することである。
【００２２】
【実施態様４】
（請求項１４に対応）
実施態様４は、上記実施態様３の製造方法について、上記予備成形品の機能面対応部及びその近傍を、使用樹脂材料のガラス転移点以上に加熱した後に加圧することである。
【００２３】
【実施態様５】
（請求項１５に対応）
実施態様５は、上記実施態様２乃至実施態様４のいずれかの製造方法について、上記予備成形品が光学機能素子の最終形状に近い形状のものであることである。
【作用】
上記予備成形品が光学機能素子の最終形状に近いものであるから、保持部材と一体化するための一体化加工における光学機能素子に対する成形加工時間を短縮し、かつ上記一体化加工における機能面の転写加工精度を向上させることができる。
【００２４】
【実施態様６】
（請求項１６に対応）
実施態様６は、実施態様５の製造方法について、上記予備成形品が射出成形品であることである。
【００２５】
【実施態様７】
（請求項１７に対応）
実施態様７は、上記解決手段、上記実施態様２乃至実施態様６のいずれかの製造方法について、上記光学機能素子の保持部材との接触面近傍を数箇所で加熱加圧して波形に変形させて保持部材の保持部と滑合させることである。
【作用】
上記光学機能素子の保持部材との接触面近傍を数箇所で加熱加圧して波形に変形させて保持部材の保持部と滑合させることで、比較的簡単容易に、所定の結合力をもった滑合部を形成することができる。
【００２６】
【実施態様８】
（請求項１８に対応）
実施態様８は、上記解決手段、実施態様２乃至実施態様６のいずれかの製造方法について、上記光学機能素子の保持部材との接触面近傍に外力を加えて、光学機能素子を保持部材の保持部と滑合させることである。
【００２７】
【実施態様９】
（請求項１９に対応）
実施態様９は、上記解決手段、実施態様２乃至実施態様６のいずれかの製造方法について、上記保持部材の光学機能素子との接触面近傍に外力を加えて、光学機能素子を保持部材の保持部と滑合させることである。
【作用】
上記外力で光学機能素子と保持部材との滑合部における樹脂を確実に変形させて、所定の保持力、結合力（摩擦抵抗力）を備えた滑合部を確実に形成することができる。
【００２８】
【実施態様１０】
（請求項２０に対応）
実施態様１０は、上記解決手段、実施態様２乃至実施態様６のいずれかの製造方法について、上記光学機能素子の光学機能面部への加圧または機能面部以外の箇所への上記外力付加によって移動した樹脂を、保持部材の内側側面に圧接させて、光学機能素子を保持部材の保持部と滑合させることである。
【作用】
上記光学機能素子の光学機能面部への加圧または機能面部以外の箇所への上記外力付加によって移動した樹脂を、保持部材の内側側面に圧接させて、光学機能素子を保持部材の保持部と滑合させることで、確実に、光学機能素子と保持部材との滑合部が接触面積の大きい形態で形成されるので、複合光学部品の精度を一層向上させることができる。
【００２９】
【実施態様１１】
（請求項２１に対応）
実施態様１１は、上記実施態様１０の製造方法について、上記光学機能素子が、保持部材と一体化加工により保持部材の保持部内側側面と圧接している間、該保持部材の保持部を外側から支持して該保持部の変形を防止することである。
【作用】
上記光学機能素子が、保持部材との一体化加工により保持部材の保持部内側側面と圧接している間、該保持部材の保持部を外側から支持して該保持部の変形を防止することで、一体化加工中の保持部材の変形が防止されるので、複合光学部品の精度を一層向上させることができる。
【００３０】
【実施態様１２】
（請求項２２に対応）
実施態様１２は、上記実施態様７乃至実施態様１１のいずれかの製造方法について、上記光学機能素子の保持部材との接触面近傍の少なくとも一部を、その素材樹脂の熱変形温度以上に加熱することである。
【作用】
上記光学機能素子の保持部材との接触面近傍の少なくとも一部を、その素材樹脂の熱変形温度以上に加熱することで、光学機能素子と保持部材との滑合部が比較的容易に形成されるので、複合光学部品の精度を向上させ、製造コストを低減することができる。
【００３１】
【実施例】
１．実施例１
次いで図２乃至図４を参照しつつ、長尺レンズアレーによる複合長尺光学部品にこの発明を適用した実施例を説明する。
この実施例１の複合長尺レンズアレーは長さ７５ｍｍ、幅２１ｍｍ，高さ８ｍｍのポリカーボネート（ガラス転移点１４０℃）製であり、保持部材（補強部材）はアルミ押出成形品である。
【００３２】
〔製造方法〕
この実施例１の製造方法は次のとおりである。
１）射出成形により機能素子（長尺レンズアレー）の最終形状に近い精度の予備成形品２０を成形する。この予備成形品２０には保持部材２１の保持部２１ａと接触する突起２０ｂを数カ所設けてある。この予備成形品２０の真直度は１４０μｍであった（図２参照）。
２）アルミ押出加工した保持部材２１の保持部２１ａの底面の長手方向中央に、プレス穴加工により中央穴２１ｂを設ける。
この保持部材２１の真直度は複合長尺光学部品の仕様よりも低くて良いから、この実施例では保持部材２１の機能素子と接触する面の真直度は５２μｍ程度にしている。
また、保持部材２１の一方の保持部２１ａの対向面に長手方向の溝２１ｃをその押出成形時に形成しており、また当該保持部２１ａの長手方向中央部に一箇所基準位置用の穴（φ１．５）２１ｄを設けている。
３）上記方法により準備した予備成形品２０を保持部材２１に挿入した後、仕上成形装置に装着する。
仕上成形装置に装着した状態で装置内ヒーターで予備成形品２０を１５０℃まで加熱し、その後、長尺レンズアレーの光学機能面を有する金型駒３１，３２で加圧して、金型駒３１，３２の光学機能面を転写する。この加圧転写中に別ヒーターにて保持部材２１の保持部２１ａを１４５℃まで加熱してこれを軟化させることで、保持部２１ａを予備成形品２０のリブ２０ａに沿った形状に変形させて滑合させる。同時に上記基準用穴２１ｄ及び上記溝２１ｃに軟化した樹脂が侵入して、上記穴２１ｄに係合し、また上記突起２０ｂが溝２１ｃになじんだ状態で嵌まり込む（図３参照）。
加圧成形後、５℃／分の速度で１３０℃まで冷却し、一体成形された複合部品を装置から取り出す（図４参照）。
【００３３】
〔結果〕
予備成形品２０及び保持部材２１の真直度が複合部品の真直度仕様（３０μｍ以下）よりもかなり低いにも関わらず、最終仕上げされた長尺レンズアレーの光学機能部の真直度は２２μｍであった。
保持部材に補強された形で離型できるため、成形離型時における光学機能部の変形及び変形のばらつきが少なく、したがって、高精度な光学機能素子が安定的に成形される。
また、基準用穴及び溝に樹脂が入り込む形となり、長尺レンズアレーが基準穴２１ｄの位置で固定され、これを固定点として熱膨張・収縮時に長手方向に摺動するので、長手方向に内部歪みを生じることはない。その結果、複合長尺レンズの使用温度範囲（−５乃至６０℃）における真直度は最大でも２８μｍ以下に抑制される。したがって、真直度を確実に基準値３０μｍ以内に維持することが出来た。
なお、長手方向の摺動抵抗の測定値の単位長さ当たりの摺動抵抗は４．８［Ｎ］であった。保持部材との熱膨張差による長尺レンズアレーの内部歪み（長手方向内部歪み）を許容範囲以内に抑制するためには、長尺レンズアレーと保持部材との、単位長さ当たりの固定力（ΔＦ）は、ΔＦ＝ａ×Ｓ×Ｅ（ただし、ａ：長尺レンズアレーの単位長さ当たりの内部歪みの許容限界、Ｓ：長尺レンズアレーの断面積、Ｅ：長尺レンズアレーの縦弾性係数）であるが、ａ＝０．００１ｍｍ，Ｅ＝０．２５×１０^１０［Ｐａ］，Ｓ＝４２ｍｍ^２を代入すると、ΔＦ＝ａ×Ｓ×Ｅ＝１０．５［Ｎ］となる。この実施例１における単位長さ当たりの摺動抵抗４．８［Ｎ］は、上記１０．５［Ｎ］の１／２以下であるから、熱膨張差による長尺レンズアレーの内部歪みによる光学特性の低下はない。
図１の上記比較対象技術における工程（成形工程＋組付工程）と比較すると、射出成形工程、組付工程が必要である点で特に違いはないが、上記予備成形品２０の成形加工精度が極めて低くても支障がないので、その射出成形サイクルを短縮することができる。したがって、長尺レンズアレー素材の射出成形工程の生産性を著しく向上させることができる。また高い組付精度が要求されて手間がかかる組付工程はないので、この実施例１によれば、図１の比較対象技術によるものに比して、複合長尺光学部品のトータル製造コストを５５％も低減することが出来た。
【００３４】
２．実施例２
実施例２は実施例１と同様に、長尺レンズアレーによる複合長尺光学部品にこの発明を適用した例であり、その複合長尺光学部品の機構、構造は実施例１と基本的に違いがない。
【００３５】
〔製造方法〕
実施例２の製造方法を図５に示している。この製造方法は基本的には実施例１と同じであるが、以下の３点で異なる。
１）射出成形品に保持部材と接触させるための突起がない点。
２）滑合させる方法が異なる点。
３）保持部材はガラス繊維で強化された樹脂素材による射出成形品を使用した点。
この実施例２では、長尺レンズアレーの予備成形品と表裏両面に突起を設けていないリブを保持部材の左右の保持部で保持させる滑合形成の方法として、予備成形品を金型駒で加圧して機能面形状を転写する際、予備成形品のリブの保持部材との接触部近傍を複数の加圧ピンにて図５に矢印Ｐ，Ｐで示すように加圧して、上下方向の外力を加えてリブを変形させる方法を採っている。これにより予備成形品のリブが図６に示すような波形となり、保持部材と数点で接した状態で滑合される。
【００３６】
〔結果〕
予備成形品及び保持部材の真直度（成形素材：１３５μｍ、保持部材：４５μｍ）が複合光学部品の真直度仕様（３０μｍ以下）よりもかなり大きいにも関わらず、複合光学部品における長尺レンズアレーの光学機能部の真直度が２５μｍであった。
また実施例２の複合長尺光学部品（長尺レンズアレーの光学複合部品）のトータルコストは上記比較対象技術によるものに比べて６５％も低減された。
この実施例２では保持部材にガラス繊維で強化した樹脂成形品を使用しているので、金属部材の加工品よりも低コストで済むという利点がある。ただし、より長尺になって高強度が必要な場合には金属部材が有利である。
【００３７】
３．実施例３
実施例３は実施例１と同様に、長尺レンズアレーによる複合長尺光学部品にこの発明を適用した例であり、その複合長尺光学部品の機構、構造は、次の点を除き実施例１と基本的に違いがない。
１）保持部材６１の保持部６１ａの内側側面に突起６１ｂを突設して、予備成形品のリブ６０ａの先端面に圧接させている点。
【００３８】
〔製造方法〕
実施例３の製造方法を図７に示している。この製造方法は基本的には実施例１と同じであるが、予備成形品のリブを保持部材の左右の保持部で保持させる滑合部分を形成する方法が異なる。
実施例３の滑合部分の形成方法は次のとおりである。
予備成形品を金型駒で加圧して機能面形状を転写する際、金型駒の加圧により加圧方向と直交する方向に移動した樹脂を、図７（ｃ）に示すように保持部材に接触させる。
加熱加圧時の樹脂圧力で保持部材が左右方向に張り出されて変形し、変形した保持部材になじむ形に予備成形品（長尺レンズアレー）が形成されるため、加圧成形後に樹脂が収縮すると、保持部材が弾性変形した分だけ復元する。そして、この保持部材の弾性復元によって反対に予備成形品（長尺レンズアレー）が押されて光学素子部まで変形し、このため光学素子部の真直度が低下してしまう。これを防止するため、保持部材の外側側面に水平方向のピンを当接させて固定し、加圧成形中の樹脂圧力による保持部材の上記変形を阻止している。
【００３９】
〔結果〕
予備成形品及び保持部材の真直度（成形素材：１４０μｍ、保持部材：５５μｍ）が複合長尺光学部品の真直度仕様（３０μｍ以下）よりもかなり大きいにも関わらず、複合長尺光学部品における長尺レンズアレーの光学機能部の真直度は２６μｍであった。
また、複合長尺光学部品のトータルコストは、上記の比較対象技術によるものに比べて５５％低減された。
この実施例３においては、樹脂が保持部材との接触面積を大きくすることができる。接触面積が大きすぎると摺動抵抗が大きくなってしまい、保持部材との熱膨張差による光学素子の内部歪みの原因になる可能性があるが、上記摺動抵抗を所定の範囲以内にすれば、この問題は回避される。他方、上記接触面積が大きくて一定の摺動抵抗がある方が、光学機能素子の保持部材による保持が安定し、複合光学部品の光学性能が安定する。
【００４０】
４．実施例４
実施例４は実施例１と同様に、長尺レンズアレーによる複合長尺光学部品にこの発明を適用した例であり、その複合長尺光学部品の機構、構造は、次の点を除き実施例１と基本的に違いがない（図８参照）。
１）長尺レンズアレーの予備成形品の下面に突起７０ｂを設け、上面に長手方向の溝７０ｃを設けた点。
２）保持部材７１の左右の保持部７１ａの上辺先端に垂直リブ７１ｂを設け、このリブ７１ｂの下を上記溝７０ｃによってガイドしている点。
【００４１】
〔製造方法〕
実施例４の製造方法を図９に示している。この製造方法は基本的には実施例１と同じであるが、次の２点において異なる。
１）保持部材を板金のプレス加工で成形した点。
２）保持部材と予備成形品（長尺レンズアレー）との基準位置を接着して固定した点。
保持部材７１と予備成形品７０のリブ７０ａとの滑合部の形成方法は次のとおりである。
予備成形品を金型駒で加圧して機能面形状を転写するときに、保持部材７１の保持部７１ａと予備成形品７０のリブ７０ａとの近傍を複数の加圧ピンで上下から加圧して、保持部７１ａを変形させて、リブ７０ａを締め付けて軽く固定する。
また、加圧成形して保持部材７１と予備成形品７０を複合化して複合光学部品を形成して後、複合光学部品を上下反転させた状態で保持部材７１の保持部下辺の長手方向中央に設けた基準位置用穴に接着剤を一滴滴下して、保持部材７１の保持部７１ａと予備成形品７０のリブ７０ａとをこの一点で固定している（図１０参照）。
【００４２】
〔結果〕
長尺レンズアレーの予備成形品７０及び保持部材７１の真直度（成形素材：１４０μｍ，保持部材：５５μｍ）が複合光学部品の真直度仕様（30μｍ以下）よりもかなり大きいにも関わらず、複合光学部品の光学機能部の真直度は２８μｍであった。
また、実施例４の複合光学部品のトータルコストは上記の比較対象技術によるものに比べて５０％低減された。
この実施例４では、保持部材と長尺レンズアレー（予備成形品）とを基準位置で接着して固定したが、これにより実施例１乃至実施例３の場合よりも基準位置における固定が確実であり、また、保持部材による光学機能素子の保持が安定するので、より精度の高い複合光学部品が得られる。
【００４３】
以上実施例１乃至実施例４について説明したが、各実施例で製造された複合光学部品は、光学機能素子と保持部材が基準位置を除き摺動可能となっており、その摺動抵抗はいずれも長さ１ｍｍ当たり６Ｎ以下であって、ΔＦ＝ａ×Ｓ×Ｅ＝１０．５［Ｎ］よりもはるかに小さい値であった。したがって、熱膨張・収縮時には光学機能素子が保持部材に対して摺動するので、光学機能素子と保持部材間の熱膨張差による光学機能素子の内部歪みを許容限度内に抑制することができ、上記熱歪みによって真直度が低下することはない。したがって、光学機能素子の光学機能低下は防止される。
さらに、光学機能素子と保持部材との複合化が、成形金型による一体化加工によってなされるから、光学機能素子の予備成形品及び低真直度の保持部材を用いて複合化することができ、したがって低コスト化が図られ、本発明の光学機能素子を使用した光学機器、光学装置は従来よりもより高機能で、しかも低コストで得られる。
また、真直度仕様が厳しい複合光学部品、例えば長尺複合光学部品において特に本発明は有効である。
したがって、長尺で真直度、面精度仕様の厳しい光学長尺素子、特にレンズアレーなどによる長尺複合光学部品について、本発明は有効であり、レンズアレー等の光学素子アレーを使用した光書き込みユニット、光読み取りユニット、及びそれらを用いたプリンターなどの画像形成装置やスキャナーなどの画像読み取り装置などを、高機能化、低コスト化するのに極めて有効である。
なお、光学機能素子と保持部材とを金型で加熱加圧して複合化するときに、機能面の面転写と滑合部形成が行われればよいのであるから、面転写と滑合部形成は必ずしも同時に行う必要はないが、コスト低減の観点からは同時に行うことが望ましい。
複合光学部品については円筒状の単レンズ、平板状の２次元レンズアレーについても上記実施例と同様に適用することができ、また、光学機能素子としては、ミラー、プリズムなどの高精度光学部品についても同様にして製造することができる。
また、複合光学部品の光学機能素子の素材が保持部材による補強を要するものであり、また、保持部材の素材が光学機能素子を保持してこれを補強できるものであれば、どのような素材の組み合わせによるかにかかわらず、この発明の適用対象になり得る。
【００４４】
【発明の効果】
この発明は以上のとおりであるが、その効果を請求項毎に纏めれば次のとおりである。
〔請求項１に係る発明の効果〕
請求項１に係る発明による複合光学部品は、光学機能素子と保持部材とを一点で互いに固定しているので、光学機能素子全体が保持部材に対して移動して位置ズレを生じることを防止できるばかりでなく、光学機能素子が保持部材に対して基準となる位置で固定されるので、複合光学部品は設計通りの高機能を発揮することができる。
また、光学機能素子が保持部材に対して遊びのない状態でしっかりと保持されるが、他方、両者は保持部によってその全長にわたって一体的に固着されているわけではないので、使用中の温度変化によって、光学機能素子が熱膨脹して保持部材に対して伸張しようとするときは、保持部による保持力に抗して光学機能素子が保持部材に対して摺動して、熱膨張による光学機能素子の内部歪みが逃がされるから、温度変化時にもその真直度が損なわれることはなく、高い光学性能を保つことができる。
【００４５】
〔請求項２に係る発明の効果〕
請求項２に係る発明の複合光学部品は、光学機能素子の基準位置が、保持部材に対してより正確な位置で確実に固定されるので、より高い光学特性を発揮することができる。
【００４６】
〔請求項３に係る発明の効果〕
請求項３に係る発明の複合光学部品は、摺動が許される方向だけに摺動させることができるので、光学機能素子の熱膨張に関わらず、高い光学性能を維持することができる。
【００４７】
〔請求項４に係る発明の効果〕
請求項４に係る発明の複合光学部品は、低真直度、低コストな保持部材を使用することができるので、低コストで高機能な複合光学部品である。
【００４８】
〔請求項５に係る発明の効果〕
請求項５に係る発明の複合光学部品は、成形性に富む樹脂材料を使用しているものであるから、容易に形成された滑合面を有し、低コストで高機能な複合光学部品である。
【００４９】
〔請求項６に係る発明の効果〕
請求項６に係る発明の複合光学部品は、樹脂に比して相当高い強度の金属材料からなる保持部材を使用しているので、高強度の複合光学部品となる。したがって、複合光学部品に撓みを与えるような負荷がかかる状況下でも、当該複合光学部品は高い光学特性を維持することができる。
【００５０】
〔請求項７に係る発明の効果〕
請求項７に係る発明の複合光学部品は、軽くて加工しやすいアルミの押出成形品を保持部材として使用するものであるから、軽量、高強度でかつ低コストな複合光学部品である。
【００５１】
〔請求項８に係る発明の効果〕
請求項８に係る発明の複合光学部品は、加工しやすい板金のプレス品を保持部材として使用するものであるから、高強度でかつ低コストな複合光学部品である。
【００５２】
〔請求項９に係る発明の効果〕
請求項９に係る発明の複合光学部品は、量産しやすいガラス繊維強化樹脂材料を保持部材として使用するものであるから、低コストで高機能な複合光学部品である。
【００５３】
〔請求項１０に係る発明の効果〕
請求項１０に係る発明の複合光学部品は、成形性に富む樹脂材料を使用しているものであるから、光学機能面の形成が容易で、かつ高精度の光学機能面を有するものである。
【００５４】
〔請求項１１に係る発明の効果〕
請求項１１に係る発明の複合光学部品の製造方法は、保持部材と光学機能素子を個別に加工して単に組付ける場合に比して、高真直度を有する複合光学部品を低コストで製造することができる。
【００５５】
〔請求項１２に係る発明の効果〕
請求項１２に係る発明の製造方法は、高精度な光学機能面を備えた光学機能素子による複合光学部品の成形時間を著しく短くすることができる。
【００５６】
〔請求項１３に係る発明の効果〕
請求項１３に係る発明の製造方法は、光学機能素子の高精度な光学機能面を確実に形成することができ、高精度かつ低コストな複合光学部品を製造することができる。
【００５７】
〔請求項１４に係る発明の効果〕
請求項１４に係る発明の製造方法は、より高精度な光学機能面を安定して確実に形成することができ、高精度かつ低コストな複合光学部品を製造することができる。
【００５８】
〔請求項１５に係る発明の効果〕
請求項１５に係る発明の製造方法は、高精度な光学機能面を備えた成形品を短時間で成形することができ、低コストで高精度の複合光学部品を製造することができる。
【００５９】
〔請求項１６に係る発明の効果〕
請求項１６に係る発明の製造方法は、最終形状に近い予備成形部品を低コストで量産できるので、低コスト、高精度で複合光学部品を製造することができる。
【００６０】
〔請求項１７に係る発明の効果〕
請求項１７に係る発明の製造方法は、所定の固定力を有する、光学機能素子と保持部材との滑合部を容易に形成することができ、低コスト、高精度の複合光学部品を容易に製造することができる。
【００６１】
〔請求項１８に係る発明の効果〕
請求項１８に係る発明の製造方法は、所定の固定力を有する、光学機能部品と保持部材との滑合部を容易に形成することができ、高精度かつ低コストな複合部品を容易に製造することができる。
【００６２】
〔請求項１９に係る発明の効果〕
請求項１９に係る発明の製造方法は、確実に樹脂を変形させて光学機能素子と保持部材の滑合部を形成することができ、高精度かつ低コストな複合光学部品を製造することができる。
【００６３】
〔請求項２０に係る発明の効果〕
請求項２０に係る発明の製造方法は、確実に光学機能素子と保持部材の滑合部を接触面積の多い形態で確実に形成できるので、高精度な複合光学部品を低コストで製造することができる。
【００６４】
〔請求項２１に係る発明の効果〕
請求項２１に係る発明の製造方法は、一体化成形加工における保持部材の変形を防止できるので、高真直度を有する複合光学部品を低コストで製造することができる。
【００６５】
〔請求項２２に係る発明の効果〕
請求項２２に係る発明の製造方法は、所定の固定力を有する、光学機能素子と保持部材との滑合部を容易に形成できるので、高性能な複合光学部品を低コストで製造することができる。
【図面の簡単な説明】
【図１】（ａ）は比較対象技術による光学機能素子（長尺レンズアレー）の正面図であり、（ｂ）は（ａ）の側面図であり、（ｃ）は比較対象技術による保持部材の正面図であり、（ｄ）は（ｃ）の側面図であり、（ｅ）は比較対象技術による複合光学部品の正面図であり、（ｆ）は（ｅ）の側面図である。
【図２】（ａ）は実施例１の光学機能素子（長尺レンズアレー）の正面図であり、（ｂ）は（ａ）の側面図であり、（ｃ）は実施例１の保持部材の正面図であり、（ｄ）は（ｃ）の側面図である。
【図３】は（ａ）は実施例１の複合光学部品の製造方法を示す正面図であり、（ｂ）は（ａ）の側面図である。
【図４】（ａ）は実施例１の複合光学部材の正面図であり、（ｂ）は（ａ）の側面図である。
【図５】（ａ）は実施例２の複合光学部品の製造方法を示す正面図であり、（ｂ）は（ａ）の側面図である。
【図６】は実施例２の複合光学部品の正面図である。
【図７】（ａ）は実施例３の複合光学部品の製造方法を示す正面図であり、（ｂ）は（ａ）の側面図であり、（ｃ）は（ｂ）におけるＡ部拡大図である。
【図８】（ａ）は実施例４の光学機能素子（長尺レンズアレー）の正面図であり、（ｂ）は（ａ）の側面図であり、（ｃ）は実施例４の保持部材の正面図であり、（ｄ）は（ｃ）の側面図である。
【図９】（ａ）は実施例４の複合光学部品の製造方法を示す正面図であり、（ｂ）は（ａ）の側面図である。
【図１０】（ａ）は実施例４の複合光学部品の正面図であり、（ｂ）は（ａ）の側面図である。
【符号の説明】
１０：長尺レンズアレー（光学機能素子）
１０ａ，２０ａ，６０ａ：リブ
１０ｂ，２０ｂ：突起
２０，７０：長尺レンズアレー（光学機能素子）の予備成形品
１１，２１，６１，７１：保持部材
１１ａ，２１ａ，６１ａ：保持部
３１，３２：金型駒
６１ｂ：突起[0001]
[Industrial application fields]
The present invention relates to a composite optical component that combines an optical functional element and a reinforcing member, prevents deformation of the optical functional element, and prevents expected functional degradation of the optical functional element due to deformation, and a method for manufacturing the same. It can reduce the thermal distortion of the optical functional element due to the difference in thermal expansion between the optical functional element and the reinforcing member due to temperature change, increase the straightness of the optical functional element, and reduce the manufacturing cost of composite parts. Thus, the present invention can be applied to various high-performance composite optical components that require straightness and high strength.
[0002]
[Prior art]
Although not a prerequisite technology of the present invention, as a conventional technology considered to be technically related, there is a “composite long material and a method for manufacturing the same” described in JP-A-8-281863. In this case, an engagement part having a lubrication surface is provided at the joint part of the composite long part having the bent part to suppress deformation, but there is no escape space for foreign matter such as wear powder on the lubrication part. There is a possibility that a foreign material may intervene in the moving part and the composite member is fixed or the sliding resistance becomes large and distortion due to deformation at the time of sliding may occur.
In addition, there is a “technical device and functional partial injection molding method” described in JP-A-7-195435. In order to ensure the function of the bearing part, a plastic film is interposed in the joint part of the outsert part and separated from the surface by the shrinkage difference after molding, but a film or the like is interposed. This is not suitable for composite functional parts that require high-precision positioning because the gap between the joint and the joint is large due to shrinkage of the resin and rattling occurs. However, since there is no escape space for foreign matter such as wear powder in the lubrication part, the composite member is intervened in the sliding part. In order to secure the function of the bearing part, a plastic film is interposed in the joint part of the outsert part, and it is separated from the surface by the shrinkage difference after molding. That is, it is unavoidable that high cost because those interposing a film.
[0003]
On the other hand, in a compound optical functional component such as a lens array that requires high accuracy, it is a major issue to ensure the required straightness in addition to partial surface accuracy. In particular, the longer the shape, the more difficult it is to ensure straightness.
In the above-mentioned composite optical functional component, in order to ensure the required straightness in addition to partial surface accuracy, it is known to perform this outsert molding by injection molding, but for cost reduction, When this is applied to a composite optical functional component such as a lens array that requires high accuracy, the resin tends to adhere to the outsert reinforcement member, and the optical functional element ( The lens or the like) is thermally distorted, or the temporary deformation of the reinforcing member due to the resin pressure during the injection molding is restored after molding by the elastic force, so that the high straightness and high surface accuracy of the optical functional element are maintained. Is difficult.
[0004]
[Comparison technology]
Long lens array (optical functional element) and reinforcing member ( Holding member 1 is shown in FIG. Since this is a separate invention from the present invention and is not a publicly known technique but is a comparison object of the present invention, an outline of the comparison object technique will be described.
Plastic long lens array (functional element) 1 0 left A rib 10a is provided on the right, and projections 10b are provided on both front and back surfaces of the rib 10a. On the other hand, holding parts 11a having a U-shaped cross section are provided on the left and right of the holding member 11 that is an aluminum extrusion molded product.
The right and left ribs 10a of the long lens array (functional element) are fitted into the holding portion 11a of the holding member 11 to be slid (stablely held and strong enough to slide against a predetermined force). The long lens array 10 is incorporated into the holding member 11 and combined to be reinforced, and the long lens array 10 is reinforced by the holding member 11.
The production procedure of the composite optical component in this comparison target technology is as follows.
1) A long lens array (optical functional element) 10 having sufficient molding accuracy with respect to the specifications is molded.
Straightness in the longitudinal direction of the functional part of the composite part: Specification 30 μm or less
Actual measurement of the functional part of the molded product Straightness : 17 μm.
2) The holding member 11 having a high straightness is formed on the surface in contact with the optical function element.
Here, an aluminum extruded product is cut to a high straightness.
Longitudinal straightness: holding member measured value 13 μm.
3) Insert the optical functional element into the holding member, and fix the contact surface at one point for reference.
Straightness of the functional part of the composite optical element: 27 μm.
As a result, the contact surface between the optical function element other than the fixed point and the holding member (the contact surface between the protrusion 10b and the holding portion 11a) is slidable but is slid without any play, so that the long lens array ( The long lens array (optical functional element) is not distorted regardless of the thermal expansion difference between the optical function element 10 and the holding member 11, and the optical performance of the long lens array is prevented from being deteriorated by the distortion.
[0005]
In the case of this comparison target technique, the straightness of the element function part of the composite part (the optical function part of the long lens array 10 in the composite part) is slightly lower than when the molded article of the long lens array 10 is alone. Since the straightness required for the molded product itself of the long lens array 10 becomes stricter than the straightness specification of the composite part, the molding cost of the long lens array 10 is high, and the holding member itself is required to have high straightness. In addition, the processing cost of the holding member is increased, and further, the assembly process between the optical functional element and the holding member is time-consuming, resulting in an increase in the cost of the combined work, resulting in an increase in the manufacturing cost of the composite long optical component. Inevitable.
[0006]
[Problems to be solved]
Therefore, the present invention prevents the optical functional element from being distorted due to thermal distortion, restoration of elastic deformation of the reinforcing member, etc., and can reduce the manufacturing cost while ensuring high straightness and high surface accuracy. Thus, the problem is to devise the structure and the manufacturing method.
[0007]
[Measures taken to solve the problem]
[Means for solving problems with composite optical components]
The means taken for the composite optical component in order to solve the above problem is that the optical functional element and the holding member are based on the premise that the optical component is composed of an optical functional element and a holding member that holds the optical functional element. That is, they are slipped by an integrated process in the molding die.
[0008]
[Action]
Since the optical functional element and the holding member are slid by the integrated process in the molding die, the optical functional element is firmly held in the state without play with respect to the holding member. Is not fixed integrally with the entire length of the holding portion. Therefore, when the optical functional element is thermally expanded due to a temperature change during use and tends to expand with respect to the holding member, the holding portion holds it. Since the optical functional element slides against the holding member against the force and the internal distortion of the optical functional element due to thermal expansion is released, the optical performance is not deteriorated by the internal distortion when the temperature changes.
Further, since the optical functional element and the holding member are outsert of the holding member and are integrally processed in the molding die, the precision-processed optical functional element and the holding member are slid together. As in the case of compounding (such as the above-mentioned comparison target technology), optical function elements are not distorted or deformed due to combination errors, etc., and optical performance does not deteriorate. It is equipped with an element, and the reliability of its performance is extremely high.
[0009]
Embodiment 1
(Corresponding to claim 1)
Embodiment 1 relates to the composite optical component of the above-mentioned solving means, wherein the contact surface of the sliding portion of the optical functional element and the holding member is Single point Are fixed to each other and the remaining contact surface is slidable. Does not cause internal distortion in the optical functional element That is.
[Action]
Contact surface of the sliding part between the optical functional element and the holding member Single point Are fixed to each other and the remaining contact surfaces are made slidable, so that the entire optical functional element does not move relative to the holding member, and the optical functional element does not move relative to the holding member. Since it is fixed at a reference position, the optical composite part can exhibit high performance as designed.
[0010]
Embodiment 2
(Corresponding to claim 2)
Embodiment 2 relates to the composite optical component of Embodiment 1 described above, the optical functional element and the holding unit. Material They are fixed to each other by a combination of uneven shapes or adhesion.
[Action]
The above-described fixing between the optical functional element and the holding member can be easily and reliably performed.
[0011]
Embodiment 3
(Corresponding to claim 3)
Embodiment 3 is the above for the composite optical component of Embodiment 1 or Embodiment 2 above. Guarantee A groove is provided in a part of the holding member or the optical functional element, and the optical functional element or the holding member in a combined state Provided in The protrusion is slidably fitted into the groove and engaged.
[Action]
Since the extension direction of the optical functional element with respect to the holding member during thermal expansion is defined as the allowable direction of the optical functional element by the engagement between the groove and the protrusion, the optical performance is hindered by the expansion of the optical element due to thermal expansion. Never happen.
[0012]
Embodiment 4
Embodiment 4 relates to the solution means, and the composite optical component of Embodiments 1 to 3, wherein the sliding resistance in the longitudinal direction of the sliding portion of the optical function element and the holding member is set in the longitudinal direction of the optical function element. That is, ΔF is within a × S × E per 1 mm.
However,
a: Allowable value of elongation of optical function element due to thermal expansion in optical system (difference in thermal expansion per unit length of holding member and optical function element)
S: sectional area of the functional part of the optical functional element
E: Elastic modulus (longitudinal elastic modulus) of optical functional element material
[Action]
By setting the sliding resistance within the above ΔF, internal strain exceeding the allowable limit of the optical function element due to the difference in thermal expansion with respect to the holding member of the optical function element is released, so the difference in thermal expansion between the optical function element and the holding member. Therefore, the internal distortion of the optical function element is reliably suppressed within a range in which the optical function is not impaired.
[0013]
Embodiment 5
(Corresponding to claim 5)
Embodiment 5 is that the portion of the composite optical component according to any one of Embodiments 1 to 3 that comes into contact with the holding member of the optical function element is a resin material.
[Action]
Since the contact portion of the optical functional element with the holding member is a resin material, the familiarity with the holding portion of the holding member is good, and therefore the entire optical element is firmly held by the holding portion, and the friction resistance against the holding portion is reduced. It is relatively easy to control within a predetermined value.
[0014]
Embodiment 6
(Corresponding to claim 6)
Embodiment 6 is that the holding member of the composite optical component according to any one of Embodiments 1 to 3 and Embodiment 5 is a metal material.
[Action]
Since the holding member (reinforcing member) is a metal material, a composite optical component having a high reinforcing effect on the optical functional element and a stable shape can be obtained.
[0015]
Embodiment 7
(Corresponding to claim 7)
Embodiment 7 is that the holding member of the composite optical component of Embodiment 6 is an aluminum extrusion-molded product or an extrusion-molded product.
[Action]
Since the holding member (reinforcing member) is made of aluminum, the holding member (reinforcing member) is lightweight and has good moldability. Therefore, a highly accurate and lightweight composite optical component can be obtained.
[0016]
[Embodiment 8]
(Corresponding to claim 8)
The eighth embodiment is that the holding member of the composite optical component of the sixth embodiment is a sheet metal pressed product.
[Action]
Since the holding member is obtained by pressing a sheet metal, its molding accuracy is high, and therefore a high-quality composite optical component can be stably obtained.
[0017]
Embodiment 9
(Corresponding to claim 9)
Embodiment 9 includes Embodiment 1 to Embodiment 3 and Embodiment Of 5 For any one of the composite optical components, the holding member is made of a resin material reinforced with glass fiber.
[Action]
Since the holding member is made of a resin material reinforced with glass fibers, the holding member is low-cost and high-strength, and thus a low-cost and high-strength composite optical component can be obtained.
[0018]
Embodiment 10
(Corresponding to claim 10)
Embodiment 10 is that the functional part of the optical functional element of the composite optical component according to any one of Embodiments 1 to 3 and Embodiments 5 to 9 is made of a resin material.
[Action]
Since the functional part of the optical functional element is made of resin, the functional surface can be transferred when the optical functional element preform and the holding member (reinforcing member) are combined. It is easy to process and is molded with high accuracy, and therefore, a composite optical component having a high functional surface can be obtained at low cost.
[0019]
[Means for solving the manufacturing method of composite optical parts]
(Corresponding to claim 11)
In order to solve the above-mentioned problem, the means taken for the method of manufacturing the composite optical component is the contact surface between the optical functional element and the holding member. Single point The optical functional surface of the mold piece is transferred to the optical functional element, the optical functional element is transferred to the optical functional element with respect to the manufacturing method of the composite optical component that is combined with the molding die so that the remaining contact surfaces are not fixed to each other. And holding member contact surface At one point in Is fixed in the same molding process.
[Action]
Mount the optical functional element and the holding member facing each other on the molding die, Single point Are fixed to each other and the optical function surface of the optical function element is transferred when the composite is made so that the remaining contact surfaces are not fixed, so that the optical function element preform and low-straightness holding member are transferred. Can be used, and the optical functional surface is transferred at the time of compounding. Therefore, the functional surface is not distorted in the compounding process, and therefore, the optical functional surface is extremely accurate at low cost. Can be efficiently manufactured.
[0020]
Embodiment 1
In the first embodiment, the manufacturing method of the solution means performs the transfer of the optical functional surface of the mold piece to the optical functional element and the sliding of the optical functional element and the holding member using different mechanisms in the same molding process. This is what I did.
[Action]
The transfer of the optical functional surface of the mold piece to the optical functional element and the sliding of the optical functional element and the holding member are performed using a different mechanism in the same molding process, so that the holding member and the optical functional element slide. Since a sliding surface having a predetermined fixing holding force can be reliably formed on the part, a highly accurate and highly accurate composite optical component can be efficiently manufactured.
[0021]
Embodiment 2
(Corresponding to claim 12)
Embodiment 2 is to transfer the optical functional surface of the die piece after inserting the preformed product into the holding member in the manufacturing method according to the above solution.
Embodiment 3
(Corresponding to claim 13)
Embodiment 3 relates to the manufacturing method of Embodiment 2, wherein the preform is a resin material, and the optical functional surface of the mold piece is transferred by moving the mold piece having the optical functional surface and pressurizing the resin. It is to be.
[0022]
Embodiment 4
(Corresponding to claim 14)
Embodiment 4 is to pressurize the functional surface corresponding part of the preform and the vicinity thereof after heating to the glass transition point or more of the resin material used in the manufacturing method of Embodiment 3 above.
[0023]
Embodiment 5
(Corresponding to claim 15)
Embodiment 5 is that, in the manufacturing method according to any one of Embodiments 2 to 4, the preform is a shape close to the final shape of the optical functional element.
[Action]
Since the preform is close to the final shape of the optical function element, the molding process time for the optical function element in the integration process for integration with the holding member is reduced, and the functional surface in the integration process is reduced. Transfer processing accuracy can be improved.
[0024]
Embodiment 6
(Corresponding to Claim 16)
Embodiment 6 is that the preform is an injection-molded product in the manufacturing method of embodiment 5.
[0025]
Embodiment 7
(Corresponding to Claim 17)
Embodiment 7 is the manufacturing method according to any one of the above-described solving means and Embodiments 2 to 6, in which the vicinity of the contact surface with the holding member of the optical functional element is heated and pressed at several places to be deformed into a waveform. It is to make it slide with the holding part of a holding member.
[Action]
By heating and pressing the vicinity of the contact surface of the optical function element with the holding member at several points to deform it into a waveform and sliding it with the holding portion of the holding member, it has a predetermined coupling force relatively easily and easily. A sliding part can be formed.
[0026]
[Embodiment 8]
(Corresponding to Claim 18)
Embodiment 8 is the above-described solution, Embodiments 2 to Embodiment 6 With respect to any one of the manufacturing methods, an external force is applied in the vicinity of the contact surface of the optical function element with the holding member to slide the optical function element with the holding portion of the holding member.
[0027]
Embodiment 9
(Corresponding to Claim 19)
Embodiment 9 is the above-described solution, Embodiments 2 to Embodiment 6 With respect to any one of the manufacturing methods, an external force is applied in the vicinity of the contact surface of the holding member with the optical function element to cause the optical function element to slide with the holding portion of the holding member.
[Action]
The resin in the sliding portion between the optical functional element and the holding member can be reliably deformed by the external force, and the sliding portion having a predetermined holding force and coupling force (friction resistance force) can be reliably formed.
[0028]
Embodiment 10
(Corresponding to Claim 20)
The tenth embodiment is the above-described solving means, the second to second embodiments. Embodiment 6 With respect to any one of the manufacturing methods, the resin moved by pressing the optical function surface portion of the optical function element or applying the external force to a portion other than the function surface portion is used as a holding member. Of The optical functional element is brought into sliding contact with the holding portion of the holding member by being brought into pressure contact with the side surface.
[Action]
Holding the resin moved by applying pressure to the optical function surface portion of the optical function element or applying the external force to a portion other than the function surface portion. Of By pressing the side surface and sliding the optical functional element with the holding part of the holding member, the sliding part between the optical functional element and the holding member is surely formed in a form with a large contact area. The accuracy of the optical component can be further improved.
[0029]
Embodiment 11
(Corresponding to Claim 21)
Embodiment 11 is the above Embodiment 10 Regarding the manufacturing method, while the optical functional element is in pressure contact with the inner side surface of the holding part of the holding member by integrated processing with the holding member, the holding part of the holding member is supported from the outside to prevent deformation of the holding part. It is to be.
[Action]
While the optical functional element is in pressure contact with the inner side surface of the holding part of the holding member by integrating with the holding member, the holding part of the holding member is supported from the outside to prevent deformation of the holding part. Since the deformation of the holding member during the integration process is prevented, the accuracy of the composite optical component can be further improved.
[0030]
Embodiment 12
(Corresponding to Claim 22)
In the twelfth embodiment, in the manufacturing method according to any one of the seventh to eleventh embodiments, at least a part near the contact surface with the holding member of the optical functional element is heated to a temperature higher than the heat deformation temperature of the material resin. That is.
[Action]
By heating at least a part near the contact surface with the holding member of the optical functional element above the heat deformation temperature of the material resin, a sliding portion between the optical functional element and the holding member is formed relatively easily. Therefore, the accuracy of the composite optical component can be improved and the manufacturing cost can be reduced.
[0031]
【Example】
1. Example 1
Then 2 to 4 An embodiment in which the present invention is applied to a composite long optical component using a long lens array will be described with reference to FIG.
The composite long lens array of Example 1 is made of polycarbonate (glass transition point 140 ° C.) having a length of 75 mm, a width of 21 mm, and a height of 8 mm, and the holding member (reinforcing member) is an aluminum extruded product.
[0032]
〔Production method〕
The manufacturing method of Example 1 is as follows.
1) The preform 20 having an accuracy close to the final shape of the functional element (long lens array) is formed by injection molding. This preform 20 is provided with several protrusions 20b that come into contact with the holding portion 21a of the holding member 21. The straightness of the preform 20 was 140 μm (see FIG. 2).
2) A central hole 21b is formed by press hole processing at the center in the longitudinal direction of the bottom surface of the holding portion 21a of the holding member 21 subjected to aluminum extrusion.
Since the straightness of the holding member 21 may be lower than the specification of the composite long optical component, in this embodiment, the straightness of the surface of the holding member 21 in contact with the functional element is set to about 52 μm.
Further, a longitudinal groove 21c is formed on the opposing surface of one holding portion 21a of the holding member 21 at the time of the extrusion molding, and a hole for a single reference position (φ1 in the longitudinal center portion of the holding portion 21a is formed. .5) 21d is provided.
3) After inserting the preform 20 prepared by the above method into the holding member 21, it is mounted on the finish molding apparatus.
The preform 20 is heated to 150 ° C. with an in-device heater in a state where it is mounted on the finish molding device, and then pressed with the die pieces 31 and 32 having the optical function surface of the long lens array. , 32 optical function surfaces are transferred. During this pressure transfer, the holding portion 21a of the holding member 21 is heated to 145 ° C. with a separate heater to soften it, thereby deforming the holding portion 21a into a shape along the rib 20a of the preform 20. Slide together. At the same time, the softened resin enters the reference hole 21d and the groove 21c and engages with the hole 21d, and the protrusion 20b fits in the groove 21c (see FIG. 3).
After the pressure molding, it is cooled to 130 ° C. at a rate of 5 ° C./min, and the integrally formed composite part is taken out from the apparatus (see FIG. 4).
[0033]
〔result〕
Even though the straightness of the preform 20 and the holding member 21 is considerably lower than the straightness specification (30 μm or less) of the composite part, the straightness of the optical function part of the final long lens array is 22 μm. It was.
Since the mold can be released in a reinforced form by the holding member, there is little deformation and variation in deformation of the optical function part at the time of mold release, and thus a highly accurate optical function element is stably molded.
Also, the resin enters the reference hole and groove, and the long lens array is fixed at the position of the reference hole 21d, and slides in the longitudinal direction during thermal expansion / contraction using this as a fixing point. There is no distortion. As a result, the straightness of the composite long lens in the operating temperature range (−5 to 60 ° C.) is suppressed to 28 μm or less at the maximum. Therefore, the straightness could be reliably maintained within the reference value of 30 μm.
In addition, the sliding resistance per unit length of the measured value of the sliding resistance in the longitudinal direction was 4.8 [N]. In order to suppress the internal distortion (longitudinal internal distortion) of the long lens array due to the difference in thermal expansion from the holding member within an allowable range, the fixing force per unit length between the long lens array and the holding member ( ΔF) is ΔF = a × S × E (where a: the allowable limit of internal distortion per unit length of the long lens array, S: cross-sectional area of the long lens array, E: vertical length of the long lens array) Elastic modulus), a = 0.001 mm, E = 0.25 × 10 ¹⁰ [Pa], S = 42mm ² Is substituted, ΔF = a × S × E = 10.5 [N]. Since the sliding resistance 4.8 [N] per unit length in Example 1 is 1/2 or less of the above 10.5 [N], the optical due to the internal distortion of the long lens array due to the thermal expansion difference. There is no deterioration in properties.
Compared with the process (molding process + assembly process) in the above-described comparison target technology in FIG. 1, there is no particular difference in that an injection molding process and an assembly process are necessary, but the molding accuracy of the preform 20 is high. Even if it is extremely low, there is no problem, and the injection molding cycle can be shortened. Therefore, the productivity of the long lens array material injection molding process can be significantly improved. In addition, since there is no assembly process that requires high assembly accuracy and takes time, the total production cost of the composite long optical component can be reduced according to the first embodiment as compared with the comparison target technique shown in FIG. It was reduced by 55%.
[0034]
2. Example 2
Example 2 is an example in which the present invention is applied to a composite long optical component using a long lens array, as in Example 1. The mechanism and structure of the composite long optical component are basically different from those of Example 1. There is no.
[0035]
〔Production method〕
The manufacturing method of Example 2 is shown in FIG. This manufacturing method is basically the same as that of Example 1, but differs in the following three points.
1) There is no protrusion for bringing the injection molded product into contact with the holding member.
2) The method of sliding is different.
3) The holding member is an injection molded product made of a resin material reinforced with glass fiber.
In this Example 2, as a method of sliding formation in which a preformed product of a long lens array and ribs not provided with projections on both the front and back surfaces are held by the left and right holding portions of the holding member, the preformed product is a mold piece. When the functional surface shape is transferred by pressing, the vicinity of the contact portion with the rib holding member of the preform is pressed with a plurality of pressing pins as indicated by arrows P and P in FIG. A method of deforming the rib by applying external force is adopted. As a result, the rib of the preformed product has a waveform as shown in FIG. 6 and is slipped in contact with the holding member at several points.
[0036]
〔result〕
Although the straightness of the preform and the holding member (molding material: 135 μm, holding member: 45 μm) is considerably larger than the straightness specification (30 μm or less) of the composite optical component, the long lens array in the composite optical component The straightness of the optical function part was 25 μm.
In addition, the total cost of the composite long optical component of Example 2 (optical composite component of the long lens array) was reduced by 65% compared to that using the above-described comparative technique.
In Example 2, since a resin molded product reinforced with glass fiber is used for the holding member, there is an advantage that the cost can be reduced compared to the processed product of the metal member. However, a metal member is advantageous when it is longer and requires high strength.
[0037]
3. Example 3
Example 3 is an example in which the present invention is applied to a composite long optical component using a long lens array, as in Example 1. The mechanism and structure of the composite long optical component are the same except for the following points. Basically no difference from 1.
1) Protrusions 61b are provided on the inner side surface of the holding portion 61a of the holding member 61 so as to be in pressure contact with the front end surface of the rib 60a of the preform.
[0038]
〔Production method〕
The manufacturing method of Example 3 is shown in FIG. This manufacturing method is basically the same as that of the first embodiment, except that a method for forming a sliding portion in which the ribs of the preform are held by the left and right holding portions of the holding member is different.
The formation method of the sliding part of Example 3 is as follows.
When pressing the preform with the die piece to transfer the functional surface shape, the resin moved in the direction perpendicular to the pressurizing direction by the press of the die piece is applied to the holding member as shown in FIG. Make contact.
The holding member is extended and deformed by the resin pressure at the time of heating and pressing, and a preformed product (long lens array) is formed in a shape that fits the deformed holding member. When contracted, the holding member is restored by the amount of elastic deformation. On the contrary, the preform (long lens array) is pushed by the elastic restoration of the holding member and is deformed to the optical element portion, so that the straightness of the optical element portion is lowered. In order to prevent this, a horizontal pin is brought into contact with and fixed to the outer side surface of the holding member to prevent the deformation of the holding member due to the resin pressure during pressure molding.
[0039]
〔result〕
Although the straightness of the preform and the holding member (molding material: 140 μm, holding member: 55 μm) is considerably larger than the straightness specification (30 μm or less) of the composite long optical component, the length in the composite long optical component The straightness of the optical functional part of the scale lens array was 26 μm.
In addition, the total cost of the composite long optical component was reduced by 55% compared to that of the above-described comparative technique.
In the third embodiment, the contact area between the resin and the holding member can be increased. If the contact area is too large, the sliding resistance will increase, which may cause internal distortion of the optical element due to the difference in thermal expansion with the holding member, but if the sliding resistance is within a predetermined range, This problem is avoided. On the other hand, when the contact area is large and there is a certain sliding resistance, the holding of the optical functional element by the holding member is stable, and the optical performance of the composite optical component is stabilized.
[0040]
4). Example 4
Example 4 is an example in which the present invention is applied to a composite long optical component using a long lens array, as in Example 1. The mechanism and structure of the composite long optical component are the following examples except for the following points. There is basically no difference from 1 (see FIG. 8).
1) Protrusions 70b are provided on the lower surface of the long lens array preform, and longitudinal grooves 70c are provided on the upper surface.
2) A point that a vertical rib 71b is provided at the top end of the left and right holding portions 71a of the holding member 71, and the bottom of the rib 71b is guided by the groove 70c.
[0041]
〔Production method〕
The manufacturing method of Example 4 is shown in FIG. This manufacturing method is basically the same as that of the first embodiment, but differs in the following two points.
1) The holding member is formed by pressing a sheet metal.
2) The reference position of the holding member and the preform (long lens array) is adhered and fixed.
A method for forming the sliding portion between the holding member 71 and the rib 70a of the preform 70 is as follows.
When the preform is pressed with a die piece to transfer the functional surface shape, the vicinity of the holding portion 71a of the holding member 71 and the rib 70a of the preform 70 is pressed from above and below with a plurality of pressing pins. The holding portion 71a is deformed and the rib 70a is tightened and lightly fixed.
Further, after forming the composite optical component by combining the holding member 71 and the preformed product 70 by pressure molding, the composite optical component is turned upside down in the center in the longitudinal direction of the lower side of the holding portion of the holding member 71. One drop of the adhesive is dropped into the provided reference position hole, and the holding portion 71a of the holding member 71 and the rib 70a of the preform 70 are fixed at this one point (see FIG. 10).
[0042]
〔result〕
Although the straightness of the preform 70 and the holding member 71 of the long lens array (molding material: 140 μm, holding member: 55 μm) is considerably larger than the straightness specification of composite optical parts (30 μm or less), the composite optics The straightness of the optical function part of the component was 28 μm.
In addition, the total cost of the composite optical component of Example 4 was reduced by 50% compared to that obtained by the above-described comparative technique.
In the fourth embodiment, the holding member and the long lens array (preliminarily molded product) are bonded and fixed at the reference position. However, the fixing at the reference position is more reliable than in the first to third embodiments. In addition, since the holding of the optical functional element by the holding member is stabilized, a more accurate composite optical component can be obtained.
[0043]
Although the first to fourth embodiments have been described above, in the composite optical component manufactured in each embodiment, the optical function element and the holding member can slide except for the reference position, and the sliding resistance is any Also, it was 6N or less per 1 mm length, which was much smaller than ΔF = a × S × E = 10.5 [N]. Therefore, since the optical functional element slides with respect to the holding member at the time of thermal expansion / contraction, the internal distortion of the optical functional element due to the difference in thermal expansion between the optical functional element and the holding member can be suppressed within an allowable limit. The straightness is not reduced by the thermal strain. Therefore, the optical function degradation of the optical functional element is prevented.
Furthermore, since the optical functional element and the holding member are combined by an integrated process using a molding die, the optical functional element can be combined using a preformed product and a low-straightness holding member, Therefore, the cost can be reduced, and the optical apparatus and optical apparatus using the optical functional element of the present invention can be obtained with higher functions and at lower cost than conventional ones.
In addition, the present invention is particularly effective for a composite optical component having a strict straightness specification, for example, a long composite optical component.
Therefore, the present invention is effective for long optical elements with long straightness and strict surface accuracy specifications, particularly long compound optical parts such as lens arrays, and an optical writing unit using an optical element array such as a lens array. In addition, the optical reading unit and an image forming apparatus such as a printer using the optical reading unit and an image reading apparatus such as a scanner are extremely effective in increasing the functionality and cost.
In addition, when the optical functional element and the holding member are combined by heating and pressing with a mold, it is only necessary to perform surface transfer of the functional surface and formation of the sliding portion. Although not necessarily performed simultaneously, it is desirable to perform them simultaneously from the viewpoint of cost reduction.
The composite optical component can be applied to a cylindrical single lens and a flat two-dimensional lens array in the same manner as in the above embodiment, and as an optical functional element, a high-precision optical component such as a mirror or a prism is used. Can be manufactured in the same manner.
In addition, the material of the optical functional element of the composite optical component needs to be reinforced by the holding member, and any material can be used as long as the material of the holding member can hold and reinforce the optical functional element. Regardless of the combination, the present invention can be applied.
[0044]
【The invention's effect】
The present invention is as described above. The effects are summarized as follows for each claim.
[Effect of the invention according to claim 1]
The composite optical component according to the invention of claim 1 includes an optical functional element and a holding member. Single point In addition to preventing the entire optical functional element from moving relative to the holding member and causing a positional shift, the optical functional element is fixed at a reference position with respect to the holding member. Therefore, the composite optical component can exhibit high functions as designed.
In addition, the optical function element is firmly held in the state where there is no play with respect to the holding member, but on the other hand, both of them are not fixed integrally over the entire length by the holding portion. Therefore, when the optical functional element is thermally expanded and tends to expand with respect to the holding member, the optical functional element slides against the holding member against the holding force by the holding portion, and the optical functional element due to thermal expansion Therefore, even when the temperature changes, the straightness is not lost and high optical performance can be maintained.
[ 0045 ]
[Effect of the invention according to claim 2]
The composite optical component of the invention according to claim 2 can exhibit higher optical characteristics because the reference position of the optical function element is reliably fixed at a more accurate position with respect to the holding member.
[ 0046 ]
[Effect of the invention according to claim 3]
Since the composite optical component of the invention according to claim 3 can be slid only in the direction in which sliding is permitted, high optical performance can be maintained regardless of the thermal expansion of the optical functional element.
[ 0047 ]
[Effect of the invention according to claim 4]
The composite optical component of the invention according to claim 4 is a low-cost and high-performance composite optical component because a holding member with low straightness and low cost can be used.
[ 0048 ]
[Effect of the invention according to claim 5]
Since the composite optical component of the invention according to claim 5 uses a resin material rich in moldability, it is a low-cost and high-performance composite optical component having an easily formed sliding surface. is there.
[ 0049 ]
[Effect of the invention according to claim 6]
Since the composite optical component of the invention according to claim 6 uses a holding member made of a metal material having a considerably higher strength than resin, it becomes a high-strength composite optical component. Therefore, the composite optical component can maintain high optical characteristics even under a situation in which a load is applied to bend the composite optical component.
[ 0050 ]
[Effect of the invention according to claim 7]
The composite optical component of the invention according to claim 7 is a light-weight, high-strength and low-cost composite optical component because it uses a light and easy-to-process aluminum extruded product as a holding member.
[ 0051 ]
[Effect of the invention according to claim 8]
The composite optical component of the invention according to claim 8 is a high-strength and low-cost composite optical component because it uses a sheet metal press that is easy to process as a holding member.
[ 0052 ]
[Effect of the Invention of Claim 9]
Since the composite optical component of the invention according to claim 9 uses a glass fiber reinforced resin material that is easily mass-produced as a holding member, it is a low-cost and high-performance composite optical component.
[ 0053 ]
[Effect of the Invention of Claim 10]
Since the composite optical component of the invention according to claim 10 uses a resin material having a high moldability, it is easy to form an optical functional surface and has a highly accurate optical functional surface.
[ 0054 ]
[Effect of the Invention of Claim 11]
According to the eleventh aspect of the present invention, there is provided a method for manufacturing a composite optical component, which manufactures a composite optical component having a high straightness at a low cost as compared with a case where the holding member and the optical functional element are individually processed and assembled. be able to.
[ 0055 ]
[Effect of the Invention of Claim 12]
The manufacturing method of the invention according to claim 12 can remarkably shorten the molding time of the composite optical component by the optical functional element having a highly accurate optical functional surface.
[ 0056 ]
[Effect of the Invention of Claim 13]
The manufacturing method according to the thirteenth aspect of the present invention can reliably form a high-precision optical functional surface of the optical functional element, and can manufacture a high-precision and low-cost composite optical component.
[ 0057 ]
[Effect of the Invention of Claim 14]
The manufacturing method according to the fourteenth aspect of the invention can stably and surely form a highly accurate optical function surface, and can manufacture a highly accurate and low-cost composite optical component.
[ 0058 ]
[Effect of the Invention of Claim 15]
The manufacturing method according to the fifteenth aspect of the present invention can form a molded product having a highly accurate optical functional surface in a short time, and can manufacture a highly accurate composite optical component at low cost.
[ 0059 ]
[Effect of the Invention of Claim 16]
The manufacturing method of the invention according to claim 16 can mass-produce preformed parts close to the final shape at low cost, and can manufacture composite optical parts with low cost and high accuracy.
[ 0060 ]
[Effect of the Invention of Claim 17]
The manufacturing method of the invention according to claim 17 can easily form a sliding portion between the optical functional element and the holding member having a predetermined fixing force, and can easily produce a low-cost, high-precision composite optical component. Can be manufactured.
[ 0061 ]
[Effect of the Invention of Claim 18]
The manufacturing method of the invention according to claim 18 is capable of easily forming a sliding portion between the optical functional component and the holding member having a predetermined fixing force, and easily manufacturing a high-precision and low-cost composite component. can do.
[ 0062 ]
[Effect of the Invention of Claim 19]
In the manufacturing method of the invention according to claim 19, the resin can be reliably deformed to form the sliding portion of the optical functional element and the holding member, and a highly accurate and low-cost composite optical component can be manufactured. .
[ 0063 ]
[Effect of the invention according to claim 20]
In the manufacturing method according to the twentieth aspect, the sliding portion between the optical functional element and the holding member can be reliably formed in a form having a large contact area, so that a highly accurate composite optical component can be manufactured at low cost. it can.
[ 0064 ]
[Effect of the invention according to claim 21]
Since the manufacturing method of the invention concerning Claim 21 can prevent a deformation | transformation of the holding member in integral molding process, the composite optical component which has high straightness can be manufactured at low cost.
[ 0065 ]
[Effect of the Invention of Claim 22]
In the manufacturing method according to the twenty-second aspect of the present invention, since the sliding portion between the optical functional element and the holding member having a predetermined fixing force can be easily formed, a high-performance composite optical component can be manufactured at low cost. it can.
[Brief description of the drawings]
1A is a front view of an optical functional element (long lens array) according to a comparison target technique, FIG. 1B is a side view of FIG. 1A, and FIG. 1C is a holding member according to a comparison target technique; (D) is a side view of (c), (e) is a front view of the composite optical component according to the comparison target technology, and (f) is a side view of (e).
2A is a front view of an optical functional element (long lens array) of Example 1, FIG. 2B is a side view of FIG. 2A, and FIG. 2C is a holding member of Example 1; (D) is a side view of (c).
3A is a front view showing the method of manufacturing the composite optical component of Example 1, and FIG. 3B is a side view of FIG. 3A.
4A is a front view of the composite optical member of Example 1, and FIG. 4B is a side view of FIG. 4A.
5A is a front view showing a method for manufacturing a composite optical component of Example 2, and FIG. 5B is a side view of FIG. 5A.
6 is a front view of the composite optical component of Example 2. FIG.
7A is a front view showing a method of manufacturing a composite optical component of Example 3, FIG. 7B is a side view of FIG. 7A, and FIG. 7C is an enlarged view of a portion A in FIG. It is.
8A is a front view of an optical functional element (long lens array) of Example 4, FIG. 8B is a side view of FIG. 8A, and FIG. 8C is a holding member of Example 4; (D) is a side view of (c).
9A is a front view showing a method of manufacturing a composite optical component of Example 4, and FIG. 9B is a side view of FIG. 9A.
10A is a front view of the composite optical component of Example 4, and FIG. 10B is a side view of FIG. 10A.
[Explanation of symbols]
10: Long lens array (optical functional element)
10a, 20a, 60a: rib
10b, 20b: protrusion
20, 70: Pre-formed product of long lens array (optical functional element)
11, 21, 61, 71: holding member
11a, 21a, 61a: holding part
31, 32: Mold piece
61b: protrusion

Claims

In a composite optical component that is reinforced by holding an optical functional element with a holding member,
The optical functional element and the holding member are fixed to each other at one point of contact surfaces of the optical functional element and the holding member, and the remaining contact surfaces are not fixed, so that the optical functional element and the holding member slide relative to each other during expansion or contraction due to heat. A composite optical component that does not cause internal distortion in an optical functional element .

The composite optical component according to claim 1, wherein the optical functional element and the holding member are fixed to each other by a combination of concave and convex shapes or adhesion.

A groove is provided in a part of the holding member or the optical functional element, projection provided on an optical functional element or the holding member is fitted slidably in a groove of the holding member or the optical functional element in the state of being combined 3. The composite optical component according to claim 1, wherein the composite optical component is engaged by being engaged.

4. The straightness in the longitudinal direction of the holding member that is in sliding contact with the optical function element is 10% or more lower than the straightness required for the optical function part of the optical function element. Any composite optical component.

Portion in contact with the hold member of the optical functional element, either composite optical component according to claim 1 to claim 4, characterized in that it consists of a resin material.

6. The composite optical component according to claim 1, wherein the holding member is made of a metal material.

The composite optical component according to claim 6, wherein the holding member is an aluminum extrusion-molded product or a press-molded extrusion-molded product.

The composite optical component according to claim 6, wherein the holding member is a press-formed product of sheet metal.

Either composite optical component according to claim 1 to claim 5 said holding member is characterized in that it consists of a resin material reinforced with glass fibers.

The composite optical component according to claim 1, wherein the functional portion of the optical functional element is made of a resin material.

Fixing the single point of contact surface of the optical functional element and the holding member with each other, so as not to secure the rest of the contact surface, a method of manufacturing a composite optical component, which is complexed by a molding die,
The transfer of the optical functional surface of the mold piece to the optical functional element and the fixing at one point on the contact surface of the optical functional element and the holding member are performed in the same molding process, and any one of claims 1 to 10 A method of manufacturing a composite optical component for manufacturing a composite optical component.

12. The method of manufacturing a composite optical component according to claim 11, wherein after the optical functional element preform is inserted into the holding member, the optical functional surface of the mold piece is transferred to the preform.

The preform is made of a resin material, and the optical functional surface of the mold piece is transferred by moving the mold piece having an optical functional surface shape and pressurizing the optical functional surface of the preform. The method for producing a composite optical component according to claim 12.

14. The method of manufacturing a composite optical component according to claim 13, wherein the functional surface corresponding portion of the preform and its vicinity are pressurized after being heated to the glass transition point or higher of the resin material used.

15. The method for manufacturing a composite optical component according to claim 12, wherein the preform is a shape close to a final shape of the optical functional element.

16. The method of manufacturing a composite optical component according to claim 15, wherein the preform is an injection molded product.

The vicinity of the contact surface of the optical functional element with the holding member is heated and pressed at several places to be deformed into a waveform, and is slid with the holding portion of the holding member. Manufacturing method of composite optical parts.

By applying an external force to the contact surface near the holding member of the optical functional element, either composite optical component according to claim 11 to claim 16, characterized in sliding engagement to be the holding portion of the holding member of the optical function element Manufacturing method.

The composite optical component according to any one of claims 11 to 16, wherein an external force is applied in the vicinity of the contact surface of the holding member with the optical function element to slide the optical function element on the holding portion of the holding member. Manufacturing method.

The resin moved by pressurizing the functional surface part of the optical functional element or applying the external force to a portion other than the functional surface part is brought into pressure contact with the inner side surface of the holding member, and the optical functional element is slid onto the holding part of the holding member. any of the processes for preparation of the composite optical component according to claim 11 to claim 16, characterized in that to.

While the optical functional element is in pressure contact with the holding part inner side surface of the holding member by integral processing molding with the holding member, the holding part of the holding member is supported from the outside to prevent deformation of the holding part. 21. A method of manufacturing a composite optical component according to claim 20 , wherein:

The composite optical component according to any one of claims 17 to 21, wherein at least part of the vicinity of the contact surface with the holding member of the optical functional element is heated to a temperature higher than a heat deformation temperature of the material resin. Method.