A high-precision injection molding system for 90-degree optical fiber arrays

Abstract

The present invention provides a high-precision injection molding system for a 90-degree optical fiber array. Compared with the prior art, the present invention includes molds for a substrate and a cover plate, a hot melt machine, an injector, an adjustment module, and a temperature adjustment module. The molds are precisely docked by guide pins to form independent mold cavities, and cooperate with the injector to achieve precise injection molding of liquid ceramic-resin composite materials. The temperature adjustment module achieves precise control of the mold temperature through dynamic preheating and cooling of the heat transfer liquid. In the preheating stage, the mold is circulated and preheated to eliminate molding defects caused by temperature differences; in the cooling stage, the coolant flow rate and temperature are adjusted in sections to ensure smooth cooling during the curing transition stage and efficient cooling after curing is completed. This system effectively improves the quality consistency and production efficiency of 90-degree optical fiber arrays.

Description

Technical Field

[0001] The present invention relates to the field of optical communication technology, and in particular to a high-precision injection molding system for a 90-degree optical fiber array. Background Art

[0002] The 90-degree array fiber optic board is a specially designed optical component that utilizes optical fibers arranged at a 90-degree angle. It is widely used in a variety of fields, including optical communications, optical sensing, fiber integration, and laser systems. Through this unique fiber arrangement, the 90-degree array fiber optic board effectively optimizes the spatial distribution of optical fibers, improves signal transmission efficiency, and reduces signal loss and interference, thereby achieving more stable and efficient optical signal transmission. It has important applications in wavelength division multiplexing (WDM) systems, fiber-to-fiber coupling, and high-density fiber optic connections. Precise fiber docking, material selection, and fiber arrangement density are all key factors affecting performance. With the increasing demand for integration and miniaturization, the 90-degree array fiber optic board will become a core component in future optoelectronic technologies, showing particularly promising applications in high-speed, high-capacity optical communications and high-power laser systems.

[0003] This experimental team has been browsing and researching a large amount of relevant records and materials on the relevant technologies of optical fiber arrays for a long time. At the same time, relying on relevant resources and conducting a large number of relevant experiments, after a large number of searches, it was found that there are existing technologies such as CN102101349B, CN111645259B and CN110320616B disclosed in the prior art. For example, the prior art discloses an integrated injection molding process for the appearance of an optical fiber connector, which includes the following steps: S1: welding, welding the optical fiber bundle to the circuit board; S2: fixing, installing the optical fiber and the circuit board on the bottom shell; S3: heat conduction and heat insulation treatment; S4: assembling the base shell, installing the top shell to the bottom shell, so that the two are plugged in and riveted to form the base shell; S5: injection molding, forming an injection-molded shell by integrated injection molding outside the base shell, and the injection molding temperature is 160-190°C; S6: connector testing, performing a connection test on the molded optical fiber connector; S7: packaging.

[0004] The present invention is made in order to solve the problems commonly existing in the field in traditional injection molding processes, such as a simple mold temperature control system, slow and uneven heating and cooling rates, which easily lead to uneven condensation of raw materials or unstable molding, affecting the consistency of products; and the inability of traditional processes to fully meet the needs of high-performance optical fiber array components when the optical fiber arrangement density is high and the dimensional tolerance requirements are strict. Summary of the Invention

[0005] The purpose of the present invention is to address the deficiencies in the current art and to propose a high-precision injection molding system for a 90-degree optical fiber array.

[0006] In order to overcome the deficiencies of the prior art, the present invention adopts the following technical solutions:

[0007] A high-precision injection molding system for a 90-degree optical fiber array includes an L-shaped substrate, optical fibers sequentially fixed to the outer wall of the substrate, and an L-shaped cover plate that can be sleeved and attached to the outer wall of the substrate. The L-shaped outer wall of the substrate is continuously provided with a plurality of parallel optical fiber grooves. These optical fiber grooves accommodate optical fibers and arrange the optical fibers in an L-shaped layout, thereby achieving 90-degree direction conversion of the optical fibers. The optical fibers are sequentially placed in each optical fiber groove, ultimately forming a 90-degree array of optical fibers. The cover plate is fixed to the outer wall of the substrate with an adhesive, thereby ensuring that the optical fibers are firmly fixed in the optical fiber grooves.

[0008] The high-precision injection molding system includes a hot melt machine for hot-melting raw materials to obtain liquid raw materials, a mold with a base plate and a cover plate shape, an adjustment module for fixing and adjusting the mold, an injector connected to the hot melt machine for simultaneously injecting the liquid raw materials into each mold, and a temperature adjustment module for assisting in regulating the temperature of the mold. The raw materials are ceramic-resin composite materials.

[0009] Furthermore, the mold includes an upper mold, a lower mold that can be fixed with the upper mold, a number of upper mold cavities independently arranged on the upper mold, and a number of lower mold cavities independently arranged on the lower mold. Each upper mold cavity has a corresponding lower mold cavity, and the matching upper mold cavity and lower mold cavity form an independent unit mold cavity, and one part of the unit mold cavity is in the shape of a substrate and the other part is in the shape of a cover plate.

[0010] Furthermore, the adjustment module includes a support base for supporting the lower mold, two upper support arms symmetrically arranged on both sides of the upper mold, a support column with the top fixedly connected to the upper support arms and the bottom fixed to the support base plate, two lower support arms symmetrically arranged on both sides of the upper mold, an electric drive lifting device with the top fixedly connected to the lower support arms and the bottom fixed to the support base, and a plurality of ultrasonic generators evenly laid on the side walls of the lower mold.

[0011] During the mold closing stage, the electric-driven lifting device precisely controls the rise of the lower mold to ensure that the lower mold and the upper mold are accurately docked, preventing manufacturing errors caused by mold misalignment. After the injection molding is completed, the electric-driven lifting device moves downward to separate the upper mold and the lower mold, thereby completing the demolding operation and ensuring that the mold can be opened smoothly and the molded substrate and cover can be removed.

[0012] Furthermore, the upper mold is provided with a plurality of material receiving ports and vents, each unit mold cavity is respectively connected with a material receiving port and a vent, a plurality of first circulation channels are provided in the upper mold, and a plurality of second circulation channels are provided in the lower mold, the first circulation channels and the upper mold cavity are independently provided, and the second circulation channels and the lower mold cavity are independently provided, each first circulation channel is sequentially surrounded by a different upper mold cavity, and each second circulation channel is sequentially surrounded by a different lower mold cavity.

[0013] The syringe is provided with multiple distribution channels, each of which is connected to an injection nozzle, each of which is connected to a material receiving port, and the flow rate of the liquid raw material delivered by each injection nozzle is adjusted by the valve of each distribution channel. The syringe delivers a quantitative amount of liquid raw material to each unit mold cavity through multiple injection nozzles.

[0014] Furthermore, the first circulation channel includes a first liquid inlet and a first liquid outlet provided on the surface of the upper mold, and the first circulation channel is in a spiral tube shape in the upper mold.

[0015] Furthermore, the second circulation channel includes a second liquid inlet and a second liquid outlet provided on the surface of the lower mold, and the second circulation channel is in a spiral tube shape in the lower mold.

[0016] Furthermore, the temperature regulating module includes a liquid collecting tank, a water source tank storing heat transfer liquid, a first liquid outlet pipe with one end connected to the water source tank, a first electric valve for controlling the communication between the first liquid outlet pipe and the water source tank, a second liquid outlet pipe with one end connected to the water source tank, a second electric valve for controlling the communication between the second liquid outlet pipe and the water source tank, a first liquid pump for controlling the flow rate of the heat transfer liquid in the water source tank from the first liquid outlet pipe, a second liquid pump for controlling the flow rate of the heat transfer liquid in the water source tank from the second liquid outlet pipe, a heater for heating the first liquid outlet pipe to control the heating temperature of the heat transfer liquid transported by the first liquid outlet pipe, a cooler for cooling the second liquid outlet pipe to control the cooling temperature of the heat transfer liquid transported by the second liquid outlet pipe, and a plurality of branches sequentially connected to all the first liquid outlet pipes. A first collecting pipe having a liquid inlet and a second liquid inlet, a second collecting pipe connecting all the first liquid outlets and the second liquid outlets in sequence through a plurality of branches, a plurality of temperature sensors for monitoring the temperature of each branch of the second collecting pipe, a Y-shaped connecting pipe with three branches, three electrically controlled valves for controlling the closing conditions of the three branches of the Y-shaped connecting pipe, a first connector for connecting one branch of the Y-shaped connecting pipe to the other end of the first liquid outlet pipe, a second connector for connecting one branch of the Y-shaped connecting pipe to the other end of the second liquid outlet pipe, a third connector for connecting one branch of the Y-shaped connecting pipe to a branch of the first collecting pipe, and a control unit for controlling the operating temperature of the heater and the cooler according to the injection molding conditions of the mold.

[0017] The beneficial effects achieved by the present invention are:

[0018] 1. Improve product quality and consistency: Through precise mold temperature control and ultrasonic vibration treatment, material defects caused by bubbles and temperature differences are significantly reduced, ensuring the quality consistency and structural stability of the 90-degree fiber array substrate and cover.

[0019] 2. Optimizing Production Efficiency: By adjusting the coolant temperature and flow rate in stages, combined with historical data analysis and multi-dimensional optimization algorithms, we optimize the entire process from preheating to cooling, significantly shortening the production cycle and improving the injection molding efficiency of substrates and cover plates.

[0020] 3. It provides reliable support for the injection molding of complex 90-degree optical fiber arrays, meeting the high-performance manufacturing needs in the field of optical communications. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present invention can be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily drawn to scale, but rather the emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate corresponding parts.

[0022] Figure 1 It is a schematic top view of part of the structure of the lower mold of the present invention.

[0023] Figure 2 This is a schematic structural diagram of the lower mold cavity of the present invention.

[0024] Figure 3 It is another structural schematic diagram of the lower mold cavity of the present invention.

[0025] Figure 4 It is a schematic front view of a partial structure of the lower mold of the present invention.

[0026] Explanation of the accompanying figures: 1-lower mold cavity; 2-second circulation channel; 3-lower support arm; 4-guide pin hole; 5-second liquid inlet; 6-second liquid outlet. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solutions and advantages of the present invention clearer, the present invention is further described in detail below in conjunction with its embodiments; it should be pointed out that the specific embodiments described herein are only used to explain the present invention and are not used to limit this case. For those skilled in the art, after reviewing the following detailed description, other systems, methods and / or features of this embodiment will become apparent. In addition, the terms describing the positional relationship in the accompanying drawings are only for illustrative purposes and cannot be understood as limiting this patent. For those of ordinary skill in the art, the specific meanings of the above terms can be understood according to the specific circumstances.

[0028] Example 1: Combined with the attached Figure 1 , Attachment Figure 2 , Attachment Figure 3 and attached Figure 4 This embodiment constructs a high-precision injection molding system for a 90-degree optical fiber array. The 90-degree optical fiber array includes an L-shaped substrate, optical fibers sequentially fixed to the outer wall of the substrate, and an L-shaped cover plate that can be sleeved and adhered to the outer wall of the substrate. The L-shaped outer wall of the substrate is continuously provided with a plurality of parallel optical fiber grooves. These optical fiber grooves accommodate optical fibers and arrange the optical fibers in an L-shaped layout, thereby achieving a 90-degree direction change of the optical fibers. The optical fibers are sequentially placed in each optical fiber groove, ultimately forming a 90-degree arranged optical fiber array. The cover plate is fixed to the outer wall of the substrate by adhesive, thereby ensuring that the optical fibers are firmly fixed in the optical fiber grooves.

[0029] The high-precision injection molding system includes a hot melt machine for hot-melting raw materials to obtain liquid raw materials, a mold with a base plate and a cover plate shape, an adjustment module for fixing and adjusting the mold, an injector connected to the hot melt machine for simultaneously injecting the liquid raw materials into each mold, and a temperature adjustment module for assisting in regulating the temperature of the mold. The raw materials are ceramic-resin composite materials.

[0030] The mold includes an upper mold, a lower mold that can be fixed with the upper mold, a plurality of upper mold cavities independently arranged on the upper mold, and a plurality of lower mold cavities independently arranged on the lower mold. Each upper mold cavity has a corresponding lower mold cavity. The matching upper mold cavity and lower mold cavity form an independent unit mold cavity, and one part of the unit mold cavity is in the shape of a substrate and the other part is in the shape of a cover plate.

[0031] Pairs of guide pins and guide pin holes are respectively arranged on the contact surfaces of the upper mold and the lower mold, wherein the guide pins are arranged on the upper mold and the guide pin holes are arranged on the lower mold. The guide pins and the guide pin holes are precisely matched to ensure that the upper mold and the lower mold can be accurately docked during the mold closing process to avoid manufacturing errors caused by displacement or misalignment. The number of pairs of guide pins and guide pin holes is greater than the number of unit cavities.

[0032] The adjustment module includes a support base for supporting the lower mold, two upper support arms symmetrically arranged horizontally on both sides of the upper mold, a support column with the top fixedly connected to the upper support arms and the bottom fixed to the support base plate, two lower support arms symmetrically arranged horizontally on both sides of the upper mold, an electrically driven lifting device with the top fixedly connected to the lower support arms and the bottom fixed to the support base, and a number of ultrasonic generators evenly laid on the side walls of the lower mold.

[0033] The top wall of each of the lower support arms is provided with at least one fixing groove, and the bottom wall of each of the support arms is provided with through-holes arranged in sequence opposite to the fixing grooves. A nut is rotatably sleeved in each through-hole through a double-row ball bearing ring, and a sealing ring is provided at the edge of the through-hole to prevent dust or impurities from entering the bearing and ensure the smooth operation of the nut. The inner groove wall of the fixing groove is provided with a thread that is threadably engaged with the nut, and a reduction motor for driving the nut to rotate the axis in the through-hole is fixed on the upper support arm through a mounting seat. The reduction motor is connected to the nut through gear transmission, worm transmission, chain transmission, ball screw or direct drive.

[0034] The reduction motor can drive in both directions. The reduction motor has a built-in encoder that can monitor the rotation angle and speed of the nut in real time. Torque sensors are installed around the penetration port to monitor the stress state of the nut. When the force monitored by the torque sensor exceeds the safety threshold, the reduction motor automatically stops operating.

[0035] During the mold closing stage, the electric-driven lifting device drives the lower mold to rise slowly through the electric-driven lifting device. When the lower mold approaches the upper mold, the guide pin and the guide pin hole begin to dock. The bidirectional rotation drive reduction motor can drive the nut to rotate clockwise according to the real-time feedback data of the torque sensor during the mold closing process, so that the nut is respectively engaged and fixed in each fixed groove to lock the upper mold and the lower mold.

[0036] After the injection molding is completed, the electric-driven lifting device lowers the lower mold at a controlled speed. At the same time, the drive nut of the reduction motor rotates counterclockwise, so that the nut moves out of each fixed slot to separate the upper mold from the lower mold, thereby completing the demoulding operation and ensuring that the mold can be opened smoothly and the molded substrate and cover can be taken out.

[0037] The ultrasonic generators are evenly arranged on the side walls of the lower mold and are used to process the liquid raw materials in the unit mold cavity through ultrasonic vibration during the injection molding process. Their main function is to eliminate tiny bubbles in the liquid raw materials. The high-frequency vibration of the ultrasonic waves can significantly reduce the bubbles in the liquid raw materials, improve the fluidity of the material, and ensure the uniformity and density of the liquid raw materials during the injection molding process, thereby avoiding the impact of bubbles on the quality of the final product.

[0038] The upper mold is provided with a plurality of material receiving ports and air vents, and each unit mold cavity is respectively connected to a material receiving port and a air vent. The upper mold is provided with a plurality of first circulation channels, and the lower mold is provided with a plurality of second circulation channels. The first circulation channels and the upper mold cavity are independently provided, and the second circulation channels and the lower mold cavity are independently provided. Each first circulation channel is sequentially arranged around a different upper mold cavity, and each second circulation channel is sequentially arranged around a different lower mold cavity.

[0039] The syringe is provided with multiple distribution channels, each of which is connected to an injection nozzle, each of which is connected to a material receiving port, and the flow rate of the liquid raw material delivered by each injection nozzle is adjusted by the valve of each distribution channel. The syringe delivers a quantitative amount of liquid raw material to each unit mold cavity through multiple injection nozzles, and the unit mold cavity of the same shape receives the same amount of liquid raw material each time, thereby ensuring quality consistency and high precision during the injection molding process.

[0040] The first circulation channel includes a first liquid inlet and a first liquid outlet provided on the surface of the upper mold. The first circulation channel is in a spiral tube shape in the upper mold.

[0041] The second circulation channel includes a second liquid inlet and a second liquid outlet provided on the surface of the lower mold. The second circulation channel is in a spiral tube shape in the lower mold.

[0042] The temperature regulating module includes a liquid collecting box, a water source box storing heat transfer liquid, a first liquid outlet pipe with one end connected to the water source box, a first electric valve for controlling the connection between the first liquid outlet pipe and the water source box, a second liquid outlet pipe with one end connected to the water source box, a second electric valve for controlling the connection between the second liquid outlet pipe and the water source box, a first liquid pump for controlling the flow rate of the heat transfer liquid in the water source box from the first liquid outlet pipe, a second liquid pump for controlling the flow rate of the heat transfer liquid in the water source box from the second liquid outlet pipe, a heater for heating the first liquid outlet pipe to control the heating temperature of the heat transfer liquid transported by the first liquid outlet pipe, a cooler for cooling the second liquid outlet pipe to control the cooling temperature of the heat transfer liquid transported by the second liquid outlet pipe, and a plurality of branches sequentially connected to all the first inlets. A first collecting pipe for the liquid inlet and the second liquid inlet, a second collecting pipe connecting all the first liquid outlets and the second liquid outlets in sequence through a plurality of branches, a plurality of temperature sensors for monitoring the temperature of each branch of the second collecting pipe, a Y-shaped connecting pipe with three branches, three electrically controlled valves for controlling the closing conditions of the three branches of the Y-shaped connecting pipe, a first connector for connecting one branch of the Y-shaped connecting pipe to the other end of the first liquid outlet pipe, a second connector for connecting one branch of the Y-shaped connecting pipe to the other end of the second liquid outlet pipe, a third connector for connecting one branch of the Y-shaped connecting pipe to a branch of the first collecting pipe, and a control unit for controlling the operating temperature of the heater and the cooler according to the injection molding conditions of the mold.

[0043] The heat transfer liquid is silicone oil or high-temperature heat transfer oil. Those skilled in the art can select the heater from existing tubular electric heaters, steam heat exchangers or electromagnetic heaters according to actual needs, and the cooler from existing compression refrigerators, water-cooled heat exchangers or thermoelectric refrigerators and other equipment, without limitation here.

[0044] The temperature regulating module first stores and supplies the heat transfer liquid through the water source tank, and the heat transfer liquid enters the heater through the first liquid outlet pipe or enters the cooler through the second liquid outlet pipe.

[0045] Before the syringe injects liquid raw materials into the mold, the temperature regulation module presets the mold. During the mold preheating stage, the first electric valve and the heater are turned on, and the heated heat transfer liquid is transported to the first collecting pipe through the Y-shaped connecting pipe and flows into the first circulation channel and the second circulation channel, thereby achieving rapid heating of the mold.

[0046] After the syringe completes injection of liquid raw materials into the mold, the temperature regulation module cools the mold. During the mold cooling stage, the second electric valve and the cooler are opened, and the path is switched through the Y-shaped connecting pipe to transport the cooled heat transfer liquid to the first collecting pipe and into the first circulation channel and the second circulation channel to reduce the mold temperature.

[0047] The control unit monitors the temperature of the heat transfer fluid in real time, dynamically adjusts the working status of the heater and the cooler, and controls the flow rate of the heat transfer fluid into the first circulation channel and the second circulation channel, thereby ensuring the stable shaping of the liquid raw material in the mold.

[0048] The heat transfer liquid in the first circulation channel and the second circulation channel is recovered to the liquid collection tank through the second collecting pipe, thereby realizing liquid recycling and reuse, reducing resource consumption and improving system efficiency.

[0049] The high-precision injection molding system of the present invention achieves full-process optimization from raw material processing to product demolding through modular design and precise control. The system of the present invention effectively solves the problems of mold misalignment, bubble residue, and uneven material defects caused by temperature differences in traditional injection molding processes, greatly improves injection molding quality and production efficiency, and meets the stringent requirements of the optical communication field for high-performance microporous plates.

[0050] Example 2: Combined with the attached Figure 1 , Attachment Figure 2 , Attachment Figure 3 , Attachment Figure 4 In addition to the contents of the above embodiments, the control unit also implements the following operation steps:

[0051] S101: Before the syringe injects the liquid material into the mold, the heater is controlled to heat the heat transfer liquid to a preheating temperature TR. At the same time, the first liquid pump controls the heat transfer liquid to flow in the first liquid outlet pipe at a preset flow rate Vr1 until the minimum temperature of all branch pipes in the second manifold reaches TR-r. The preheating operation of the mold is completed, where TR∈[135℃, 200℃], r is a fluctuation value, r∈[20℃, 30℃], ℃ is degrees Celsius,

[0052] S102: After the syringe completes the injection of liquid raw materials into the mold, the mold is cooled. The second liquid pump drives the heat transfer liquid to flow in the second liquid outlet pipe at a flow rate of Vr2. The cooler cools the heat transfer liquid to a temperature of Td until Tem max When the preset cooling temperature Tex is reached, the cooling process is completed, the substrate and cover in the mold are solidified, and the demolding conditions are met.

[0053] During the cooling phase, the specific operating parameters of Td and Vr2 are as follows:

[0054] ,

[0055] ,

[0056] Among them, V1 is slow flow rate, V2 is gentle flow rate, V3 is fast flow rate, Trf is the melting point of raw materials, μ is the adjustment parameter, Tem max It is the maximum temperature of all branches in the second collecting pipe currently monitored by the temperature sensor in real time, μ∈[10℃,25℃], V1<V2<V3, V3∈[10 L / min,25 L / min], V2∈[7 L / min,15 L / min], V1∈[3 L / min,6 L / min].

[0057] Wherein, Td1, Td2 and Td3 are obtained by the following calculation:

[0058] , α is the slow cooling coefficient, α∈[0.6,0.9];

[0059] , β1 is the steady cooling coefficient, β2 is the logarithmic correction coefficient used to adjust the dynamic change of steady cooling, β1∈[0.3,0.6], β2∈[0.1,0.4];

[0060] , γ is the rapid cooling coefficient, γ∈[0.3,0.7].

[0061] The operating code of the control unit is as follows:

[0062] class TemperatureControlUnit:

[0063] def __init__(self, tr_min, tr_max, r_min, r_max, vr1_min, vr1_max,vr2_min, vr2_max):

[0064] self.TR_min = tr_min

[0065] self.TR_max = tr_max

[0066] self.r_min = r_min

[0067] self.r_max = r_max

[0068] self.Vr1_min = vr1_min

[0069] self.Vr1_max = vr1_max

[0070] self.Vr2_min = vr2_min

[0071] self.Vr2_max = vr2_max

[0072] self.current_temperature = 0

[0073] def preheat(self, TR, Vr1):

[0074] print(f"Starting preheat process: Target Temperature = {TR}℃, FlowRate = {Vr1} L / min")

[0075] while True:

[0076] self.current_temperature += (TR - self.current_temperature) * 0.1

[0077] min_temp = self.current_temperature - (self.r_min + self.r_max) / 2

[0078] print(f"Current Temperature: {self.current_temperature:.2f}℃,Minimum Temperature: {min_temp:.2f}℃")

[0079] if min_temp>= TR - self.r_max:

[0080] print("Preheat process complete.")

[0081] break

[0082] def cool_down(self, Td, Vr2, Tex):

[0083] print(f"Starting cooling process: Cooling Temperature = {Td}℃, FlowRate = {Vr2} L / min")

[0084] while True:

[0085] self.current_temperature -= (self.current_temperature - Td) * 0.1

[0086] print(f"Current Temperature: {self.current_temperature:.2f}℃")

[0087] if self.current_temperature<= Tex:

[0088] print("Cooling process complete. Mold ready for demolding.")

[0089] break

[0090] TR = 150

[0091] r = 25

[0092] Vr1 = 5

[0093] Vr2 = 15

[0094] Td = 50

[0095] Tex = 30

[0096] tcu = TemperatureControlUnit(tr_min=135, tr_max=200, r_min=20, r_max=30, vr1_min=3, vr1_max=6, vr2_min=7, vr2_max=25)

[0097] print("--- S101: Preheat Phase ---")

[0098] tcu.preheat(TR, Vr1)

[0099] print("--- S102: Cooling Phase ---")

[0100] tcu.cool_down(Td, Vr2, Tex).

[0101] In this embodiment, the specific values ​​of parameters α, β1, β1, γ, μ, V1, V2, and V3 are derived from a comprehensive adjustment of historical data analysis, experimental calibration, operating condition simulation, multi-dimensional optimization algorithm, and actual operating conditions. By analyzing historical operating data to extract key influencing factors, combined with experimental calibration to verify the specific effects of different parameters on the mold cooling effect, numerical simulation and multi-dimensional optimization algorithm are then used to optimize the parameter contribution ratios, and dynamically adjust them under actual production conditions to ensure that the parameter values ​​meet the production quality of substrates and cover plates while achieving maximum optimization of the injection molding production efficiency of substrates and cover plates.

[0102] The control unit achieves dynamic adjustment of the mold temperature through precise preheating and cooling control to meet the requirements of the injection molding process. During the preheating stage, the control heater heats the heat transfer liquid to the preset temperature TR and circulates it through the first liquid outlet pipe at a flow rate Vr1, so that the mold reaches a uniform preheating state and eliminates molding defects that may be caused by excessive initial temperature differences in the mold.

[0103] During the transition stage of raw material solidification, in order to ensure the uniformity of temperature distribution in the mold and avoid stress or cracks caused by rapid temperature changes during the raw material solidification process, the coolant flow rate is reduced to make the cooling process more stable. On the contrary, when the raw material solidification is completed, in order to improve production efficiency, the coolant flow rate is gradually increased to quickly remove heat and accelerate the cooling of the entire mold, ensuring that the mold temperature reaches the preset cooling temperature as soon as possible, creating conditions for the demolding operation.

[0104] The control unit of the present invention achieves precise management of mold temperature through full-process optimization of preheating, cooling and dynamic control, meeting the temperature requirements at different stages of the injection molding process. It not only improves cooling efficiency, but also significantly improves the quality of the substrate and cover plate and the consistency of material properties, providing reliable support for the efficient production of complex 90-degree optical fiber arrays.

[0105] Although the present invention has been described above with reference to various embodiments, it will be appreciated that many changes and modifications may be made without departing from the scope of the present invention. That is, the methods, systems, and devices discussed above are examples. Various configurations may omit, replace, or add various processes or components as appropriate. For example, in alternative configurations, the methods may be performed in an order different from that described, and / or various components may be added, omitted, and / or combined. Moreover, the features described with respect to certain configurations may be combined in various other configurations, such as different aspects and elements of the configurations may be combined in a similar manner. In addition, as technology develops, the elements therein may be updated, i.e., many elements are examples and do not limit the scope of the present disclosure or claims. It will also be appreciated that, after reading the contents of the present invention, a technician may make various changes or modifications to the present invention, and these equivalent changes and modifications also fall within the scope defined by the claims of the present invention.

Claims

1. A high-precision injection molding system for a 90-degree optical fiber array, comprising an L-shaped substrate, optical fibers sequentially fixed to the outer wall of the substrate, and an L-shaped cover plate capable of being sleeved and adhered to the outer wall of the substrate. The L-shaped outer wall of the substrate is continuously provided with a plurality of parallel optical fiber grooves, which accommodate optical fibers and arrange them in an L-shaped layout, thereby achieving 90-degree directional conversion of the optical fibers. Optical fibers are sequentially placed into each optical fiber groove, ultimately forming a 90-degree array of optical fibers. The cover plate is fixed to the outer wall of the substrate with an adhesive, thereby ensuring that the optical fibers are firmly fixed in the optical fiber grooves. It is characterized by: The high-precision injection molding system includes a hot melt machine for hot-melting raw materials to obtain liquid raw materials, molds having the shapes of a base plate and a cover plate, an adjustment module for fixing and adjusting the molds, an injector connected to the hot melt machine for simultaneously injecting the liquid raw materials into each mold, and a temperature adjustment module for assisting in regulating the temperature of the molds. The raw materials are ceramic-resin composite materials. The mold includes an upper mold, a lower mold capable of being fixedly engaged with the upper mold, a plurality of upper mold cavities independently provided on the upper mold, and a plurality of lower mold cavities independently provided on the lower mold, each upper mold cavity has a matching lower mold cavity, and the matching upper mold cavity and lower mold cavity form an independent unit mold cavity, and one part of the unit mold cavity is in the shape of a substrate and the other part is in the shape of a cover plate; The adjustment module includes a support base for supporting the lower mold, two upper support arms symmetrically arranged on both sides of the upper mold, a support column with the top fixedly connected to the upper support arms and the bottom fixed to the support base, two lower support arms symmetrically arranged on both sides of the lower mold, an electric drive lifting device with the top fixedly connected to the lower support arms and the bottom fixed to the support base, and a plurality of ultrasonic generators evenly laid on the side walls of the lower mold. During the mold closing phase, the electrically driven lifting device precisely controls the rise of the lower mold to ensure accurate docking between the lower and upper molds, preventing manufacturing errors caused by mold misalignment. After injection molding is completed, the electrically driven lifting device descends to separate the upper and lower molds, completing the demoulding operation and ensuring smooth mold opening and removal of the molded substrate and cover. The upper mold is provided with a plurality of material receiving ports and air vents, and each unit mold cavity is respectively connected to a material receiving port and a air vent. The upper mold is provided with a plurality of first circulation channels, and the lower mold is provided with a plurality of second circulation channels. The first circulation channels and the upper mold cavity are independently provided with each other, and the second circulation channels and the lower mold cavity are independently provided with each other. Each first circulation channel surrounds a different upper mold cavity in turn, and each second circulation channel surrounds a different lower mold cavity in turn. A plurality of distribution channels are provided in the syringe, each distribution channel is connected to an injection nozzle, and each injection nozzle is connected to a material receiving port, and the flow rate of the liquid raw material delivered by each injection nozzle is adjusted by the valve of each distribution channel. The syringe delivers a quantitative amount of liquid raw materials to each unit mold cavity through multiple injection nozzles.

2. The high-precision injection molding system according to claim 1, characterized in that: The first circulation channel includes a first liquid inlet and a first liquid outlet provided on the surface of the upper mold. The first circulation channel is in a spiral tube shape in the upper mold.

3. The high-precision injection molding system according to claim 2, characterized in that: The second circulation channel includes a second liquid inlet and a second liquid outlet provided on the surface of the lower mold. The second circulation channel is in a spiral tube shape in the lower mold.

4. The high-precision injection molding system according to claim 3, characterized in that: The temperature regulating module includes a liquid collecting box, a water source box storing heat transfer liquid, a first liquid outlet pipe with one end connected to the water source box, a first electric valve for controlling the connection between the first liquid outlet pipe and the water source box, a second liquid outlet pipe with one end connected to the water source box, a second electric valve for controlling the connection between the second liquid outlet pipe and the water source box, a first liquid pump for controlling the flow rate of the heat transfer liquid in the water source box from the first liquid outlet pipe, a second liquid pump for controlling the flow rate of the heat transfer liquid in the water source box from the second liquid outlet pipe, a heater for heating the first liquid outlet pipe to control the heating temperature of the heat transfer liquid transported by the first liquid outlet pipe, a cooler for cooling the second liquid outlet pipe to control the cooling temperature of the heat transfer liquid transported by the second liquid outlet pipe, and a plurality of branches sequentially connected to all the first inlets. A first collecting pipe for the liquid inlet and the second liquid inlet, a second collecting pipe connecting all the first liquid outlets and the second liquid outlets in sequence through a plurality of branches, a plurality of temperature sensors for monitoring the temperature of each branch of the second collecting pipe, a Y-shaped connecting pipe with three branches, three electrically controlled valves for controlling the closing conditions of the three branches of the Y-shaped connecting pipe, a first connector for connecting one branch of the Y-shaped connecting pipe to the other end of the first liquid outlet pipe, a second connector for connecting one branch of the Y-shaped connecting pipe to the other end of the second liquid outlet pipe, a third connector for connecting one branch of the Y-shaped connecting pipe to a branch of the first collecting pipe, and a control unit for controlling the operating temperature of the heater and the cooler according to the injection molding conditions of the mold.

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