Method and apparatus for producing a structure, molding tool

Patent metadata

Field	Value
Publication number	US-8945458-B2
Application number	US-201113314904-A
Country	US
Kind code	B2
Filing date	Dec 8, 2011
Priority date	Dec 21, 2009
Publication date	Feb 3, 2015
Grant date	Feb 3, 2015

Abstract

A method of producing a structure from curable material by molding includes arranging a molding tool above a surface, so that in a region between the molding tool and the surface, the curable material adjoins the surface and a molding face of the molding tool which faces the surface, and so that additional curable material may continue to flow into the region. The method further includes irradiating the curable material in the region in a locally varying manner, so that the curable material cures at different speeds in a laterally varying manner and that shrinkages occurring during curing of the curable material are compensated for by the additional curable material. The method further includes applying a constant pressure to the additional curable material. Moreover, a second method and an apparatus for producing a structure from curable material by molding and a molding tool for an optical component are described.

First claim

The invention claimed is:

1. A method of producing a structure from curable material by molding, the method comprising:
arranging a molding tool for an optical component, comprising:
a molding face comprising a surface region for defining an optically relevant surface of the optical component, the molding tool being transparent to irradiation from a side which faces away from the molding face; and
a membrane layer arranged on the molding face, said membrane layer loosely abutting the molding face in a channel region of the molding face which is laterally adjacent to the surface region, being expandable and being connected, around the channel region, to the molding face in a fluid-tight manner, so that an expandable channel is formed between the molding face and the inner surface of the membrane layer,

so that the molding faces the surface with not-yet cured curable material being located between the molding face and the surface and so that not the surface is distanced from the channel region with the not-yet cured curable material located between the surface and the expandable channel;
irradiating the curable material in the surface region in a locally varying manner, so that the not-yet cured curable material cures at different speeds in a laterally varying manner, and
during the irradiation, applying a pressure within the expandable channel of the molding tool so as to expand the expandable channel and cause a flow of the not-yet cured curable material into the surface region such that shrinkages occurring during curing of the not-yet cured curable material in the surface region are compensated for by the not-yet cured curable material.

2. The method as claimed in claim 1 ,
wherein said locally varying irradiation is performed, through the molding tool, from a side of the molding tool which faces away from the molding face.

3. The method as claimed in claim 1 ,
wherein the local variation of the irradiation is performed by a displacement of two apertures comprising locally varying transparencies and/or by a gray filter comprising electrically and/or mechanically adjustable variable transparency.

4. The method as claimed in claim 1 ,
wherein the locally varying irradiation is performed at least partly through a structure for beam diffusion.

5. The method as claimed in claim 1 ,
said method comprising producing a plurality of structures; and
the local variation of the irradiation being performed by shifting two aperture fields comprising fixed individual apertures, a distance of the individual apertures corresponding to the distance of the structures to be produced.

6. The method according to claim 1 , wherein the molding tool comprises a plurality of surface regions for defining an optically relevant surface of a plurality of optical components, wherein the membrane layer is formed so that the expandable channel extends laterally adjacent the plurality of surface regions or, for each of the plurality of surface regions, a separate expandable channel is provided laterally adjacent to the respective surface region.

Assignees

• Wippermann Frank
• Duparre Jacques
• Dannberg Peter
• Braeuer Andreas
• Fraunhofer Ges Forschung

Inventors

• Wippermann Frank
• Duparre Jacques
• Dannberg Peter
• Braeuer Andreas

Classifications

• B29C35/0894

  provided with masks or diaphragms · CPC title

• B29C37/005

  Compensating volume or shape change during moulding, in general · CPC title

• B29C33/405

  Elastomers, e.g. rubber (B29C33/50 takes precedence) · CPC title

• B29D11/00442 Primary

  Curing the lens material · CPC title

• B29C2035/0827

  using UV radiation · CPC title