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研究生: 湯峻清
Jyun-Cing Tang
論文名稱: 非球面陣列透鏡之射出成形研究
Research on Aspheric Lens Array by Injection Molding
指導教授: 陳炤彰
Chao-Chang A. Chen
口試委員: 楊申語
Sen-Yeu Yang
趙修武
Shiu-Wu Chau
沈永康
Yung-Kang Shen
黃國政
Kuo-Cheng Huang
學位類別: 碩士
Master
系所名稱: 工程學院 - 機械工程系
Department of Mechanical Engineering
論文出版年: 2011
畢業學年度: 99
語文別: 中文
論文頁數: 283
中文關鍵詞: 非球面陣列透鏡射出成形模具照明用光學元件相機鏡頭
外文關鍵詞: Aspheric Lens Array, Injection molding, Mold, Illumination optical element, Camera lens
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本研究設計與製造非球面陣列透鏡(Aspheric Lens Array, ALA)作為成像與照明兩種用途之光學元件。在本研究中,將探討成像用非球面陣列透鏡(Aspheric Lens Array for Image, ALA_M)之透鏡的成形複製與成像品質。透鏡性質包含鏡片高度(Sag)、非球面形狀誤差(Rt)、翹曲(Warpage)、有效焦長(Effective Focal Length, EFL)、波前誤差(Wavefront errors)、調制轉換函數(Modulation Transfer Function, MTF)和光斑直徑(Spot Diameter, Ds),最後再藉由ALA_M於可調控焦距機制之成像品質測試,藉此探討模具溫度對於成形與光學品質之影響性。實驗結果發現,當模具溫度為90oC時,非球面形狀誤差之最小平均值為1.088 μm。應用可調控焦距機構於ALA_M時,可得到最小調控距離平均值為2.58 mm。ALA_M的非球面形狀誤差、有效焦長、波前誤差、光斑直徑與模具溫度有關。在照明用非球面陣列透鏡(Aspheric Lens Array for Illumination, ALA_L)之照明性質(Illuminance)方面,藉由所設計之ALA_L改善LED之中心照度值。從ALA_L(照明)之中心照度實驗結果中,得知ALA_L(照明)之中心照度值由51.4勒克斯(lux)提升到56.2勒克斯(lux),有效提高8.53%。本研究成果可應用於下世代之多透視相機鏡頭與多鏡頭陣列。


This research is to design and fabricate two type of Aspheric Lens Array (ALA) for image (M) and illumination (L). In this research, the Aspheric Lens Array for Image (ALA_M) has been studied to investigate the relationship between molding replicate of lens and optical image properties. Typical lens properties including Sag, form error (Rt), warpage, effective focal length (EFL), wavefront errors, modulation transfer function (MTF) and spot diameter (Ds) have been measured and discussed. An adjust-focal-length mechanism has been developed to test optical image properties. For ALA_M, the Rt can be achieved as 1.088μm when the mold temperature is set at 90oC during injection molding. The minimum average delta length (△L) as low as 2.58mm can be achieved when the ALA_M is used with adjust-focal-length mechanism. From experimental results, the mold temperature significantly affects on the aspheric form error, effective focal length, wavefront error and spot diameter of ALA_M. For the Aspheric Lens Array for Illumination (ALA_L), the center illuminance has been measured by light meter. From experiment results, the center illumination of the ALA_L can be improved from the original 51.4 lux to 56.2 lux. This research results can be used for the next generation multi-perspective camera and multi-camera lens array.

摘要 I Abstract II 致謝 III 目錄 IV 圖目錄 X 表目錄 XX 符號表 XXIII 第一章 導論 1 1.1研究背景 1 1.2研究目的 6 1.3研究方法 10 1.4論文架構 14 第二章 文獻回顧 16 2.1光學分析相關文獻 16 2.2成形收縮相關文獻 19 2.3透鏡陣列相關文獻 22 2.4相關專利文獻回顧 31 2.5文獻回顧總結 40 第三章光學與射出成形理論應用 52 3.1陣列透鏡設計應用 52 3.1.1光學透鏡設計(幾何光學)理論[50] 52 3.1.2 Surface Sag (鏡片高度) 54 3.1.3陣列透鏡位置設計 56 3.2成形收縮 58 3.2.1射出成形之收縮定義 58 3.2.2影響收縮之因素 59 3.3形狀精度與波前誤差 64 3.3.1形狀精度[50] 64 3.3.2波前誤差[50] 65 3.4聚焦偏移(Focus Shift) 70 3.5成像用非球面陣列透鏡(ALA_M)誤差關係分析 72 第四章 光學設計與模流分析 73 4.1非球面透鏡設計與分析 76 4.1.1非球面透鏡設計 78 4.1.2非球面透鏡之光學品質分析 79 4.2成像用非球面陣列透鏡(ALA_M)和照明用非球面陣列透鏡(ALA_L)之設計與分析 87 4.2.1成形收縮之光學分析 89 4.2.2雷射光斑分析 90 4.2.3照明用非球面陣列透鏡(ALA_L)之LED與3D幾何設計 93 4.2.4照明用非球面陣列透鏡(ALA_L)之照明模擬分析 96 4.3 模流分析 104 4.3.1前處理、塑膠材料選擇、參數設定 105 4.3.2成像用非球面陣列透鏡(ALA_M)之z軸翹曲與殘留應力探討 107 4.3.3照明用非球面陣列透鏡(ALA_L)之流動波前與核心溫度探討 111 4.4模具設計 113 4.4.1成像用非球面陣列透鏡(ALA_M)模具設計 113 4.4.2照明用非球面陣列透鏡(ALA_L)模具設計 118 第五章 實驗設備與規劃 121 5.1實驗設備 121 5.1.1射出成形設備 122 5.1.2量測設備 124 5.2射出成形實驗規劃 129 5.2.1取樣方法 130 5.2.2短射實驗 (Short-shot experiment) 130 5.2.3成形視窗實驗 136 5.2.4實驗參數設定 138 5.2.5不同模溫之成形壓力曲線 139 5.3非球面陣列透鏡之成形檢測 145 5.3.1非球面透鏡輪廓 145 5.3.2翹曲(Warpage)探討 146 5.4光學品質檢測 149 5.4.1有效焦長(EFL)檢測 151 5.4.2成像品質(Image quality)檢測 154 5.4.3光斑直徑(Spot Diameter)檢測 158 5.4.4中心照度(Illumiance)檢測 159 第六章 實驗結果與討論 161 6.1非球面陣列透鏡透鏡之成形性探討 161 6.1.1 輪廓形貌 161 6.1.2 形狀誤差 165 6.2 z軸收縮量與光學品質之關係 170 6.2.1 有效焦長 (Effective Focal Length, EFL) 170 6.2.2 實際有效焦長(EFL)檢測 173 6.2.4 波前誤差 (Wavefront errors) 176 6.2.5 成像品質探討 178 6.2.6 調控聚焦品質探討 181 6.2.7 聚焦品質探討 185 6.2.8 調制轉換函數(MTF)探討 188 6.3 照明(Illumination)品質探討 192 6.4 殘留應力分析 194 6.5 成像用非球面陣列透鏡(ALA_M)之誤差量探討 197 6.6 結果與討論總結 199 第七章 結論與建議 202 7.1 結論 202 7.2 建議 206 參考文獻 207 附錄A Aspheric lens data 212 附錄B 全電式射出成形機 FANUC ROBOSHOT α15-ia 215 附錄C Asahi Kasei Delpet 80NH PMMA 物性表 216 附錄D Asahi Kasei Delpet 80N PMMA 物性圖 217 附錄E 石英壓力感測器KISTLER 9204B 218 附錄F 實驗模具BOM 219 附錄G-1 實驗模具_固定側_爆炸圖 220 附錄G-2 實驗模具_可動側_爆炸圖 221 附錄G-3 實驗模具_ALA_M_設計圖 222 附錄G-4 實驗模具_ALA_L_設計圖 223 附錄H UA3P 224 附錄I Veeco Dektak 6M Stylus Profiler 225 附錄J Taylor Hobson Form Talysurf PGI 1240 226 附錄K CMM 227 附錄L WAT- 202D Camera 228 附錄M 形狀誤差 229 附錄N 干涉條紋圖 231 附錄O FIZEAU 干涉儀 234 附錄P Wellypower LED 規格表 235 附錄Q 校徽之成像檢測 236 附錄R 幾何光學 239 附錄S 成像判定方法 246 附錄T 雷射光束介紹 248 附錄U 照明 250 作者簡介 254

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