Abstract:
A method of manufacturing an optical component is provided. The method comprises steps of providing a first liquid; providing a fluid, disposed above the first liquid, wherein an interface exists between the first liquid and the fluid; providing a polymer precursor at the interface; and solidifying the polymer precursor so as to form the optical component made by a polymer.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a method of manufacturing optical components, and more particularly to a method of manufacturing optical components of polymers. 
       BACKGROUND OF THE INVENTION 
       [0002]    Presently the optical components, such as lenses, could be classified into two categories in general, which are glass lenses and plastic lenses. In comparison, glass lenses can endure high temperature and slightly higher transmittance than plastic lenses, but glass lenses are much more fragile and their manufacturing hours are ten times longer than that of plastic ones because of several grind processes usually used in manufacture, and thus the production costs are much higher. 
         [0003]    Plastic lenses have advantages of fast manufacture and cheap cost for mass production. However, plastic lenses usually use some manufacturing techniques such as injection molding or die casting to produce, and all these need precise molds, yet a set of precise molds always cost hundreds of thousands of dollars. For the precise mold of non-spherical lenses, the price is even higher. Besides, the manufacture for precise molds always takes one month or longer to finish, and therefore plastic lenses are suitable for the market of mass demand in order to recover the cost of precise molds. 
         [0004]    Hence, in order to solve the problems of the expensive price and the long production time of precise molds, to utilize the resources on the Earth economically, to make plastic lenses suitable for production types of mass quantity but few varieties as well as great varieties but less quantity simultaneously, and to further shorten the lead time of production, the present invention provides a novel concept and solution to solve the abovementioned issues effectively and to lower the production cost substantially. 
       SUMMARY OF THE INVENTION 
       [0005]    In accordance with one aspect of the present invention, a method of manufacturing an optical component is provided. The method comprises steps of providing a first liquid; providing a fluid, disposed above the first liquid, wherein an interface exists between the first liquid and the fluid; providing a polymer precursor at the interface; and solidifying the polymer precursor so as to form the optical component made by a polymer. 
         [0006]    Preferably, the first liquid is a glycerin. 
         [0007]    Preferably, the step of providing the polymer precursor at the surface is performed by using one of a manual syringe and an electric dispenser. 
         [0008]    Preferably, the fluid is one of a second liquid and a gas. 
         [0009]    Preferably, the second liquid is a silicon oil. 
         [0010]    Preferably, the polymer precursor has a density smaller than that of the first liquid, but greater than that of the fluid. 
         [0011]    Preferably, the polymer is one of a thermosetting polymer and a thermoplastic polymer. 
         [0012]    Preferably, when the polymer is the thermosetting polymer, the step of solidifying the polymer precursor comprises at least one selected from a group consisting of photocuring, thermocuring or dual-part curing. 
         [0013]    Preferably, the method further comprises a step of providing a frame in the liquid for at least one of positioning the polymer precursor and adjusting a shape of the polymer precursor. 
         [0014]    Preferably, the optical component has a surface roughness smaller than 10 mm. 
         [0015]    In accordance with another aspect of the present invention, a method of manufacturing an optical component is provided. The method comprises steps of providing a fluid; providing a substrate disposed in the fluid; providing a polymer precursor on the substrate; and solidifying the polymer precursor so as to form the optical component made by a polymer. 
         [0016]    Preferably, the fluid is one of a liquid and a gas. 
         [0017]    Preferably, the substrate is a glass. 
         [0018]    Preferably, the step of providing a polymer precursor into the liquid is performed by using a manual syringe and an electric dispenser. 
         [0019]    Preferably, the polymer precursor has a density greater than that of the fluid. 
         [0020]    Preferably, the polymer is one of a thermosetting polymer and a thermoplastic polymer. 
         [0021]    Preferably, when the polymer is the thermosetting polymer, the step of solidifying the polymer precursor comprises at least one selected from a group consisting of photocuring, thermocuring or dual-part curing. 
         [0022]    Preferably, the optical component has a surface roughness smaller than 10 nm or has a radius ranged from 0.35 mm to 2 mm. 
         [0023]    In accordance with a further aspect of the present invention, a method of manufacturing an optical component is provided. The method comprises steps of providing a liquid; providing a polymer precursor into the liquid; and solidifying the polymer precursor so as to form the optical component made by a polymer. 
         [0024]    Preferably, the liquid is a glycerin. 
         [0025]    Preferably, the step of providing the polymer precursor into the liquid is performed by using one of a manual syringe and an electric dispenser. 
         [0026]    Preferably, the polymer is one of a thermosetting polymer and a thermoplastic polymer. 
         [0027]    Preferably, when the polymer is the thermosetting polymer, the step of solidifying the polymer precursor comprises at least one selected from a group consisting of photocuring, thermocuring and dual-part curing. 
         [0028]    Preferably, the polymer precursor has a density close to that of the liquid. 
         [0029]    Preferably, the method further comprises a step of providing a frame in the liquid for at least one of positioning the polymer precursor and adjusting a shape of the polymer precursor. 
         [0030]    Preferably, the optical component has a surface roughness smaller than 10 nm or has a diameter ranged from 200 μm to 600 μm. 
         [0031]    The above objects and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed descriptions and accompanying drawings, in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]      FIGS. 1A-1B  show the optical component production processes according to the first embodiment of the present invention; 
           [0033]      FIGS. 2A-2C  show the optical component production processes according to the second embodiment of the present invention; 
           [0034]      FIGS. 3A-3B  show the optical component production processes according to the third embodiment of the present invention; and 
           [0035]      FIGS. 4A-4B  show the optical component production processes according to the fourth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0036]    The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for the purposes of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed. 
       First Embodiment 
       [0037]      FIGS. 1A-1B  show the optical component production processes according to the first embodiment of the present invention. Please refer to  FIG. 1A . Firstly, the liquid  12  is filled into the container  10  (e.g. glycerin, silicon oil, salt solution, sugar solution, etc., or any fluid whose characteristics like specific gravity or surface tension can be adjusted). Then, the injector  16  of the electric dispenser (the hand-pushed syringe can be used instead) is put into the liquid  12 . Next, a polymer precursor  14  is dispensed from the injector  16  into the liquid  12  (otherwise, the injector  16  can be put above the surface of the liquid  12  and dispense the polymer precursor thereinto). Please refer to  FIG. 1B . Subsequently, the injector  16  is removed and the polymer precursor  14  in the liquid  12  is solidified so as to form an optical component  14   a  constituted by polymer. Because the pressure from every direction to a point in the liquid is equivalent, the optical component  14   a  will become spherical, and the size of which is determined by the amount of the injected polymer precursor  14 . 
         [0038]    As to the method of solidifying, it is possible to use the photocurable process, for example use the UV light to solidify because of the rapid solidifying velocity and the short solidifying time, or use the thermocurable process or the dual-form curable process which possesses faster reacting velocity. 
         [0039]    It is likely to choose the liquid whose density (i.e. the specific gravity) is equivalent to that of the polymer precursor  14 , and which does not generate chemical reaction with or dissolve with the polymer precursor  14 , as the liquid  12 . Therefore the polymer precursor  14  will float within the liquid  12  instead of precipitating in or drifting on the liquid  12 . 
         [0040]    The method of manufacturing the optical component in this embodiment has the advantages of fast production velocity, no mold requirement, and adjusting the size of the optical component freely and rapidly according to the demand without changing multiple sets of molds. Since the cost of plastic material is low but that of molds is high, and the manufacturing time of molds is long, the method of manufacturing the optical component in this embodiment can lower the production cost and shorten the lead time of production substantially, and achieve a special efficacy of almost real-time production. 
       Second Embodiment 
       [0041]      FIGS. 2A-2C  show the optical component production processes according to the second embodiment of the present invention. Please refer to  FIG. 2A . Firstly, a frame  28  is set in the container  20  and a liquid  22  (e.g. glycerin) is poured thereinto. The frame  28  may include two circle frames on the upside and downside, as shown in  FIG. 2A . Please refer to  FIG. 2B . Next, the injector  26  of the electric dispenser insert liquid  22  is put at the location between the upside circle frame and the downside circle frame, and the polymer precursor  24  is dispensed from the injector  26  into the liquid  22 . When the amount of the injected polymer precursor  24  is great enough to contact the two circle frames, the polymer precursor  24  will be oval-shaped, as shown in  FIG. 2B , because of the compression of the circle frames. Please refer to  FIG. 2C . Then, the injector  26  is removed and the polymer precursor  24  in the liquid  22  is solidified so as to form an optical component  24   a  constituted by polymer, wherein the shape of the optical component  24   a  is oval. 
         [0042]    Therefore, by adjusting the respective diameters of the upside and the downside circle frames of the frame  28  as well as the distance therebetween, and the amount of the injected polymer precursor  24 , the oval-shaped bodies with different volumes, sizes, and cambers can be manufactured, thereby defining the optical components with different optical parameters like the focal length or else. Furthermore, the respective diameters of the upside circle frame and the downside circle frame can be different. When the two diameters are different, the respective cambers on the upside and downside of the optical component manufactured will be different. This diversifies the optical design possess. 
         [0043]    On the other hand, if the polymer precursor  24  does not contact the upside circle frame and the downside circle frame simultaneously, i.e. not compressed by the two frames, it is spherical. Adjusting the relative sizes of the circle frames and the polymer precursor  24  appropriately can confine the polymer precursor  24  in the two circle frames without floating away. At this moment, the circle frames have the function of alignment to prevent two polymer precursor  24  spheres from colliding and transforming before solidifying. Alternatively, the frames are not necessary to be round-shaped; they can be triangles, squares, hexagons or octagons. 
         [0044]    When putting into mass production in practice, arrays of injectors are available, e.g. 8×8 arrays, 64 injectors 26 totally; frames 28 can also use 8×8 arrays, 64 sets of the upside circle frame and downside circle frame totally. In this case, 64 optical components  24   a  can be produced simultaneously in one production cycle, which is a huge elevation of production efficiency. Certainly, the amount of units in the arrays can be increased or decreased properly based on the practical demand. In addition, the amount of the polymer precursor  24  dispensed from each syringe in the arrays as well as the respective diameters of the upside circle frame and the downside circle frame and the distance therebetween can be different, so that the production for optical components  24   a  in one lot can be distinguishable in size and shape, making the production more elastic and convenient. 
       Third Embodiment 
       [0045]      FIGS. 3A-3B  show the optical component production processes according to the third embodiment of the present invention. Please refer to  FIG. 3A . Firstly, the first liquid  32   a  is filled into the container  30  (e.g. glycerin, silicon oil, salt solution, sugar solution, etc., or any fluid whose characteristics like specific gravity or surface tension can be adjusted). Next, a fluid  32   b  is filled into the container  30 . The fluid  32   b  can be a second liquid (e.g. silicon oil, vegetable oil, mineral oil or any other liquid which is not oil and whose specific gravity is lighter than that of the first liquid  32   a ). Since the first liquid  32   a  and the fluid  32   b  will not dissolve with each other, an interface will be formed between the first liquid  32   a , such as glycerin, and the fluid  32   b , such as silicon oil. Subsequently, the injector  36  of the electric dispenser (the hand-pushed syringe could be used instead) is put into the interface between the first liquid  32   a  and the fluid  32   b , and the polymer precursor  34  is dispensed from the injector  36  into the interface. The injector  36  is not necessary to be put into the location of the interface. Since the specific gravity of the polymer precursor  34  is between those of the two liquids, the polymer precursor  34  will sink or float to the location of the interface eventually. Please refer to  FIG. 3B . Then, the injector  36  is removed and the polymer precursor  34  located on the interface is solidified so as to form an optical component  34   a  constituted by polymer. 
         [0046]    The liquid which does not generate chemical reaction with or dissolve with the polymer precursor  14  can be chosen as the first liquid  32   a  and the fluid  32   b . When the density of the first liquid  32   a  is greater than that of the polymer precursor  34 , and the density of the polymer precursor  34  is greater than that of the fluid  32   b , the polymer precursor  34  will suspend in the interface between the first liquid  32   a  and the fluid  32   b.    
         [0047]    In this embodiment, it is possible to change the hydraulic pressure from the upside layer and the downside layer to the polymer precursor  34  on the interface by adjusting the respective densities of the first liquid  32   a , the fluid  32   b  and the polymer precursor  32 , so as to adjust the cambers on the upside and the downside of the manufactured optical component  34   a.    
         [0048]    On the other hand, the surface tension of the first liquid  32   a , the fluid  32   b  and the polymer precursor  34  will also affect the variation of the camber, so it is possible to add some additives like the leveling agent or else in the polymer precursor  34  to adjust the surface tension thereof, or add some dissolvable additives in the first liquid  32   a  and/or the fluid  32   b  to adjust the surface tension thereof. 
         [0049]    In this embodiment, all methods in the first embodiment can be used in the solidifying method for the polymer precursor  34 , which will not be described repeatedly. 
         [0050]    Additionally, the fluid  32   b  in this embodiment can be other fluids as well, e.g. gas. In this case, the polymer precursor  34  will float on the first liquid  32   a . By adjusting the respective densities of the first liquid  32   a  and the polymer precursor  34  as well as the air pressure of the fluid  32   b , the cambers on the upside and downside of the manufactured optical component  34   a  can be adjusted. 
         [0051]    On the other hand, it is possible to combine the method of this embodiment with that of the second embodiment, i.e. disposing two circle frames on the upside and the downside of the interface between the first liquid  32   a  and the fluid  32   b  respectively, so as to further define and design the cambers on the upside and the downside of the polymer precursor  34 . 
       Fourth Embodiment 
       [0052]      FIGS. 4A-4B  show the optical component production processes according to the fourth embodiment of the present invention. Please refer to  FIG. 4A . Firstly, a liquid  41  is filled into the container  40  (e.g. glycerin, silicon oil, salt solution, sugar solution, etc., or any fluid whose characteristics like specific gravity or surface tension can be adjusted). Next, a substrate  42  is disposed in the liquid  41 , and a polymer precursor  44  is dispensed from the injector  43  of the electric dispenser (the hand-pushed syringe could be used instead) onto the substrate  42 . Please refer to  FIG. 4B . Then, the injector  43  is removed and the polymer precursor  44  on the substrate  42  is solidified so as to form an optical component  44   a  constituted by polymer. 
         [0053]    The liquid which does not generate chemical reaction with or dissolve with the polymer precursor  44 , and whose density is smaller than that of the polymer precursor  44 , can be chosen as the liquid  41 . Since the density of the polymer precursor  44  is greater than that of the liquid  41 , the polymer precursor  44  will maintain its position on the substrate  42  without floating in the liquid  41 . Instead of choosing a liquid in this embodiment, other fluids will also be available, such as gas. Besides, the material of the substrate  42  could be glass or anything pervious to light, depending on what is suitable for integration with MEMS devices or other applications using the optical component  44   a  comprising the substrate  42 . 
         [0054]    In this embodiment, it is possible to change hydraulic pressure for the polymer precursor  44  by adjusting the respective densities of the liquid  41  and the polymer precursor  44  so as to adjust the camber of the manufactured plano-convex optical component  44   a . Alternatively, the method described in the previous embodiment where additives are added in the liquid  41  or the polymer precursor  44  to adjust the surface tension can be used as well. In addition, the solidifying methods for the polymer precursor  14  in the first embodiment can also be used in this embodiment. 
         [0055]    For the optical components manufactured with the method of the present invention, the surface roughness thereof is smaller than 10 nm. Besides, the diameter of the manufactured ball lens is ranged from 200 μm to 600 μm, and the radius of the plano-convex lens is ranged from 0.35 mm to 2 mm. 
         [0056]    In conclusion, the present invention provides a method of manufacturing optical components without the requirement of the expensive and complicated precise mold. This makes the plastic lens and the plastic optical component suitable for the production type of mass quantity but few varieties or great varieties but less quantity simultaneously, and further shortens the lead time of production, thereby substantially elevating the production capability and enormously lowering the production cost. 
         [0057]    While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.