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CN-122018058-A - Curved fly-eye lens and manufacturing method and manufacturing mold thereof

CN122018058ACN 122018058 ACN122018058 ACN 122018058ACN-122018058-A

Abstract

The invention relates to the technical field of micromachining, in particular to a curved fly-eye lens and a manufacturing method and a manufacturing mould thereof, wherein the manufacturing method comprises the steps of S10, establishing a plane lens three-dimensional model comprising a plurality of sub-eyes, S20, printing the plane lens three-dimensional model by adopting a 3D printing technology, S30, evenly covering a smooth layer on the surface of the plane lens three-dimensional model, then carrying out silanization treatment to obtain a master model, S40, carrying out mould turning treatment to the master model to obtain a flexible negative mould for re-engraving the master model morphology, S50, forming a curved cavity by negative pressure molding by the flexible negative mould, and injecting photosensitive resin into the curved cavity and carrying out ultraviolet curing. The invention can manufacture the micro lens array with the high-order aspheric profile by combining the 3D printing technology, and meanwhile, the defects of high surface roughness and insufficient precision of the 3D printing element are effectively overcome by the design of the smooth layer, so that the lens after copying has excellent optical performance.

Inventors

  • LIU YONGSHUN
  • SUN MINGYANG
  • ZHANG ZIJIAN
  • LU GEYU

Assignees

  • 吉林大学

Dates

Publication Date
20260512
Application Date
20260413

Claims (10)

  1. 1. The manufacturing method of the curved fly-eye lens is characterized by comprising the following steps: S10, establishing a planar lens three-dimensional model comprising a plurality of sub-eyes; s20, printing the planar lens three-dimensional model by adopting a 3D printing technology; s30, evenly covering a smooth layer on the surface of the planar lens three-dimensional model, and then performing silanization treatment to obtain a master model; s40, performing mold turning treatment on the female mold to obtain a flexible negative mold for re-engraving the shape of the female mold; s50, forming a curved cavity by negative pressure molding of the flexible negative mold, injecting photosensitive resin into the curved cavity, and performing ultraviolet curing.
  2. 2. The method for manufacturing the curved fly-eye lens according to claim 1, wherein the step S10 comprises obtaining structural parameters of each sub-eye through Zemax optical simulation, constructing a three-dimensional model file in SolidWorks according to the structural parameters, importing the three-dimensional model file into Zemax, and verifying through ray tracing in a non-sequence mode to ensure that focuses of all the sub-eyes can uniformly fall on a detector on the same plane.
  3. 3. The method of claim 1, wherein the sub-eye consists of a cylindrical base and an aspherical crown disposed on top of the cylindrical base.
  4. 4. The method for manufacturing a curved fly-eye lens according to claim 1, wherein the smooth layer is a photoresist layer, and the step S30 comprises spraying a photoresist layer on the surface of the master model, leveling, and drying to uniformly cover the photoresist layer on the surface of the master model.
  5. 5. The method for manufacturing a curved fly-eye lens according to claim 1, wherein the step S40 comprises: preparing PDMS prepolymer and performing first vacuumizing and defoaming; placing the master model into a mould customized according to the size of the master model, and pouring the PDMS prepolymer into the mould; And carrying out secondary vacuumizing and defoaming on the PDMS prepolymer in the die so as to remove bubbles among sub-eyes generated in the pouring process.
  6. 6. The curved fly-eye lens is characterized by comprising a lens main body and a plurality of aspheric sub-eye lenses integrated on the lens main body, wherein the aspheric sub-eye lenses comprise a first-stage aspheric sub-eye lens positioned at the center of the top of the lens main body, and two-N-stage aspheric sub-eye lenses which are symmetrically and annularly arranged by taking the first-stage aspheric sub-eye lens as a center and extend towards the periphery, and the caliber and the aspheric coefficients of the aspheric sub-eye lenses change along with the progressive increment, wherein N is a natural number which is more than 2 and less than 6.
  7. 7. The curved fly-eye lens according to claim 6, wherein the aspherical sub-eye lens is composed of a cylindrical base lens and an aspherical crown lens disposed on top of the cylindrical base lens, the aspherical crown lens satisfying the formula: Wherein, the At the height s, the curved surface is sagittal in the direction of the optical axis; radial coordinates, i.e. the perpendicular distance from the optical axis; is the apex curvature, i.e., the curvature of the curved surface portion; The basic conical surface type of the surface is determined as a conical constant; the even order surface coefficient is a coefficient for describing the deviation amount of the surface with respect to the basic conical surface.
  8. 8. The manufacturing die for the curved fly-eye lens is characterized by comprising a master die, wherein the master die comprises a planar lens three-dimensional model comprising a plurality of sub-eyes, a smooth layer arranged on the planar lens three-dimensional model and a release layer formed by silanization, wherein the planar lens three-dimensional model is printed by adopting a 3D printing technology.
  9. 9. The mold for manufacturing a curved fly-eye lens according to claim 8, further comprising a flexible negative mold for reproducing the master mold morphology and a molding die having a smooth curved surface, wherein the flexible negative mold can be attached to the smooth curved surface of the molding die by suction under negative pressure, so that the flexible negative mold can form a curved surface cavity for accommodating a photosensitive resin.
  10. 10. The mold for manufacturing a curved fly-eye lens according to claim 8, wherein the smooth layer is a photoresist layer and the thickness of the photoresist layer is less than 3 μm.

Description

Curved fly-eye lens and manufacturing method and manufacturing mold thereof Technical Field The invention belongs to the technical field of micromachining, and particularly relates to a curved fly-eye lens, a manufacturing method thereof and a manufacturing die thereof. Background The artificial fly-eye lens is used as a bionic optical element, simulates the structure of an insect fly-eye, integrates a plurality of tiny lens units on a substrate, has the advantages of sensitivity to moving objects, wide field of view, strong anti-interference performance and the like, and has great application potential in a plurality of fields. In the medical field, a novel endoscope designed based on the principle of artificial fly-eye lenses can provide a wider field of view for doctors by virtue of the characteristic of a wide field of view, so that in-vivo tissues can be observed more accurately. In the consumer electronics field, in virtual reality and augmented reality devices, artificial fly-eye lenses can improve optical imaging quality, bringing more immersive experience to users. In unmanned aerial vehicle obstacle avoidance field, the core help of artifical fly-eye lens lies in providing super wide angle, high speed, low-power consumption's visual perception ability for unmanned aerial vehicle to greatly promoted the efficiency and the reliability of obstacle avoidance in complicated, dynamic environment. In order to realize the preparation of the small-sized aspheric compound eye, scientific researchers have proposed various technological methods, and the main processing technology comprises: 1. The femtosecond laser etching process includes focusing femtosecond laser onto quartz, silicon chip and other substrate to form concave micro lens array pit, etching with chemical solution to optimize the smoothness of the pit, and finally pouring PDMS into the pit, curing and demolding to obtain the compound eye array. The method has high precision, but has multiple steps and high cost of laser equipment, and is suitable for small-batch preparation in laboratories. 2. The hot press forming process includes the first making metal or ceramic mother mold with microlens array, heating polycarbonate, optical resin and other thermoplastic material to soften state, applying pressure to the mother mold to make the material adhere to the mother mold grain, cooling and demolding to obtain the compound eye lens. The method is suitable for batch production, the cost is lower than that of a laser process, but the processing difficulty of a master model is high, and the optical performance of the material can be reduced due to high temperature. 3. The photoresist hot melting process includes coating photoresist on the substrate, etching the photoresist layer to form cylindrical array, heating the substrate in a heating stage to shrink the photoresist layer with surface tension to form hemispherical or aspheric surface, and cooling to obtain compound eye. The method has low equipment threshold, but the micro lens has narrow focal length adjusting range and poor glue layer temperature resistance. It can be seen that the above methods have a number of problems and limitations in the preparation of fly-eye lenses. As micro-optical devices become more demanding for "small volume, high image quality, and low cost", existing technologies have failed to meet the technological breakthrough needs. Therefore, the development of the small-sized aspheric compound eye preparation process which has the advantages of simplified steps, low cost and mass production and can be compatible with the precision and the materials has very important significance. With the development of 3D printing technology, the advantages of the 3D printing technology in the aspect of manufacturing complex three-dimensional structures are increasingly prominent. However, currently mainstream optical 3D printing technology is limited by factors such as materials, printing resolution, surface roughness, and the like, and directly printed optical elements often cannot meet the precision and surface quality requirements of traditional optical processing, especially in the aspect of aspheric optical surfaces. How to combine the advantages of flexible 3D printing with the high precision and high quality surfaces required by traditional optical devices to achieve efficient, low cost preparation of complex aspheric fly-eye lenses remains a current technical challenge. Disclosure of Invention In view of the above, the invention aims to provide a curved fly-eye lens, a manufacturing method and a manufacturing mold thereof, the advantages of flexible manufacturing of complex surface structural members are utilized by utilizing a 3D printing technology, and the low-cost, high-efficiency and high-precision manufacturing of the optical-grade small-sized aspheric fly-eye lens is realized by combining with a fine surface post-treatment and mold turning technology. In order to achieve the