Methods for producing molding die, wafer lens, and optical lens
AssigneeKonica Minolta, Inc.
InventorsKatsuki Furuta, Hiroyuki Matsuda
Life of this patent
Estimating the term…
Abstract
A resin amount for forming each first-stage resin layer portion (a first-stage resin replica portion) 41da in a first process is defined to be greater than a resin amount for forming each second-stage resin layer portion (a second-stage resin replica portion) 41db in a second process. Therefore, at a boundary between the first-stage resin layer portion 41da and the second-stage resin layer portion 41db, a joint portion 48 at which resin overlaps is formed, whereby occurrence of an undercut shape can be avoided. Therefore, in a molding process using a sub-master die 40 and a sub-sub-master die 50 obtained from the sub-master die 40, occurrence of an undesired shape can be avoided, whereby mold release resistance can be reduced or eliminated.
Claims19
A method for producing a molding die, in which the molding die includes a plurality of resin replica portions that are obtained by molding the plurality of resin replica portions on a first substrate by repeatedly using a master die, which comprises a first molding surface on which a shape corresponding to an optical lens is formed, the method comprising:
- a first process of forming, at one of alternate positions of a checkerboard pattern of the first substrate, a plurality of first-stage resin replica portions among the plurality of resin replica portions by disposing a resin material between the master die and the first substrate;
- a second process of forming, at the other of alternate positions of the checkerboard pattern of the first substrate, a plurality of second-stage resin replica portions among the plurality of resin replica portions by disposing the resin material between the master die and the first substrate,
- wherein, in the second process, each of the second-stage resin replica portions is formed such that a side edge of each of the second-stage resin replica portions overlaps a side edge of each of the first-stage resin replica portions formed in the first process.
A method for producing a molding die, in which the molding die includes a plurality of resin replica portions that are obtained by molding the plurality of resin replica portions on a first substrate by repeatedly using a master die, which comprises a first molding surface on which a shape corresponding to an optical lens is formed, the method comprising:
- a first process of forming, at one of alternate positions of a checkerboard pattern of the first substrate, a plurality of first-stage resin replica portions among the plurality of resin replica portions by disposing a resin material between the master die and the first substrate;
- a second process of forming, at the other of alternate positions of the checkerboard pattern of the first substrate, a plurality of second-stage resin replica portions among the plurality of resin replica portions by disposing the resin material between the master die and the first substrate,
- wherein, in the second process, each of the second-stage resin replica portions is formed such that an end of each of the second-stage resin replica portions overlaps an end of each of the first-stage resin replica portions formed in the first process,
- wherein during the first process a portion of the resin extends by a distance, P, from an edge of the master die at the one of alternative positions of the checkerboard pattern of the first substrate toward the other of alternate positions of the checkerboard pattern of the first substrate, wherein 0.5 G<P<G, wherein G is defined to be a distance between the master die, when present at the one of alternative positions of the checkerboard pattern of the first substrate during the first process, and the master die, when present at the other of alternative positions of the checkerboard pattern of the first substrate during the second process.
Dependencies are inferred from the claim text.