Composite optical component and its manufacturing method

Optical: systems and elements – Lens – With support

Reexamination Certificate

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C359S813000, C359S822000, C029S458000, C029S527200

Reexamination Certificate

active

06791771

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a composite optical component formed by combining a functional device with a holding member and a method for manufacturing the composite optical component wherein the aforementioned functional device comprises a high-precision plastic molded product (especially such an optical device as a lens, prism and mirror) used in an optical scanning system such as a copying machine, facsimile machine, solid-stage scanning type printer, image reading apparatus and image writing apparatus.
2. Description of the Prior Art
In recent, one of requirements for such equipment as a copying machine, facsimile machine and optical printer head is to reduce the size (to achieve a smaller space and cost). This is accompanied by an essential requirement for thin-walled configuration of such an optical component as a lens.
An optical component made of plastic material has a smaller material rigidity, so especially a functional device (optical device) for a thin-walled and long-sized lens or the like is subjected to deformation when exposed to a slight load, with the result that straightness deteriorates.
To solve this problem, it is considered that the functional device is formed into a composite optical component using a higher rigid material (hereinafter referred to as “holding member”) such as metal.
However, when the aforementioned composite optical component is formed by injection molding (“insert” and “outsert”), the following problems will arise; straightness deteriorated by difference in shrinkage resulting from close adhesion between the two in a cooling step, and changes in straightness due to changing temperatures in the operating environment, because of a great difference in linear expansion coefficients between the functional device and holding member.
To solve this problem, it is considered to effect separation treatment to be provided between the functional device and holding member, but no effective material is found out at present, and no effective method can be expected.
An object of the present invention is to solve the aforementioned issues and to provide a composite optical component and a method for manufacturing it, capable of ensuring the straightness of a functional device in the operating environment (changes in temperature).
SUMMARY OF THE INVENTION
(First Invention)
The invention is characterized in that a functional device is sandwiched by a holding member, and a composite body is formed. The present invention has such a configuration provides a simple and effective method wherein, once a composite body is formed, there is only a small change in straightness under loads and in the operating environment (changes in temperature).
The present invention is characterized in that a functional device is caulked by a holding member to form a composite body. The invention arranged in the aforementioned manner provides a simple and effective method wherein, once a composite body is formed; there is only a small change in straightness under loads and in the operating environment (changes in temperature).
The invention is characterized in that a functional device is sandwiched by a holding member, and a composite body is formed through plastic deformation of the functional device. The present invention having such a configuration provides an effective method wherein, once a composite body is formed, there is only a small change in straightness under loads and in the operating environment (changes in temperature). Furthermore, improved engagement between the functional device and holding member is ensured by plastic deformation. Since this engaged portion serves as a guide, superb straightness can be maintained even if misalignment is caused by linear expansion coefficient in the operating environment (changes in temperature).
The invention is characterized in that a functional device is caulked by a holding member, and a composite body is formed through plastic deformation of the functional device. The invention having such a configuration provides an effective method wherein, once a composite body is formed, there is only a small change in straightness under loads and in the operating environment (changes in temperature). Furthermore, improved engagement between the functional device and holding member is ensured by plastic deformation. Since this engaged portion serves as a guide, superb straightness can be maintained even if misalignment is caused by linear expansion coefficient in the operating environment (changes in temperature).
The invention is characterized in that a functional device is press-fitted into a holding member, and a composite body is formed through plastic deformation of the functional device. The invention having such a configuration provides an effective method wherein, once a composite body is formed, there is only a small change in straightness under loads and in the operating environment (changes in temperature). Furthermore, improved engagement between the functional device and holding member is ensured by plastic deformation. Since this engaged portion serves as a guide, superb straightness can be maintained even if misalignment is caused by linear expansion coefficient in the operating environment (changes in temperature).
The invention is characterized in that a holding member or functional device is subjected to elastic deformation and are fixed together. Then the functional device is heated and is subjected to plastic deformation to reduce the stress between two components, thereby allowing the holding member and functional device to slide-fit with each other. According to the invention having such a configuration, the holding member is subjected to elastic deformation first, and is fixed to the functional device. Then the functional device is heated in excess of thermal deformation temperature and is softened, and the installation portion of the functional device is deformed by the resilient restoring force of the holding member. Furthermore, the functional device is solidified by cooling, and a clearance is formed due to the difference in shrinkage of two components, whereby a composite body is formed. Here, the resilient restoring force of the holding member is employed to allow slide-fitting between the functional device and holding member. As a result, direct force is generated between two components, thereby ensuring slide-fitting of excellent engagement. Furthermore, no external force is used. This feature provides a simple configuration and low cost of the apparatus.
The invention is characterized in that a holding member is subjected to elastic deformation to sandwich a functional device. The present invention having such a configuration allows the holding member to sandwich the functional device by subjecting it to elastic deformation.
The invention is characterized in that a holding member is subjected to elastic deformation and a functional device is staked. The invention having such a configuration allows the holding member to be subjected to elastic deformation and the functional device to be caulked.
The invention is characterized in that a functional device is subjected to elastic deformation and is press-fit into a holding member. The invention having such a configuration allows the functional device to be subjected to elastic deformation and to be press-fit into the holding member.
The invention is characterized in that the steps of holding a functional device by a holding member to be formed into a composite body; elastic-deforming the holding member or functional device to fix the holding member and functional device together, heating the functional device, and plastic-deforming to reduce stress between two components, thereby allowing the holding member and functional device to slide-fit with each other, and transfer of the shape of molding die functional surface are carried out in one and the same process. The invention having such a configuration allows the shape of the molding die functional surface to be transferred in one and the same proces

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