A linear light guide injection molding post structure capable of realizing no gate residue
Patent Information
- Application Number
- CN202522044265.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-23
- Publication Date
- 2026-09-29
- Estimated Expiration
- 2035-09-23
AI Technical Summary
[0004]1、浇口残留问题：浇口一般采用手工切割或激光切割，切割后的浇口不仅容易存在断面粗糙和断面倾斜的问题，而且若残留高度≥0.2mm，则会导致线形光导的局部光反射异常
[0016]1、无浇口残留和光学缺陷：在线形光导的端部延长形成非功能性工艺段，将浇口设置在非功能性工艺段，再在注塑成型以后将整个非功能性工艺段进行切除，避免了传统设计中浇口残留导致的亮斑问题，亮斑消除率100％，提高了线形光导整体发光的均匀性，提高了光学和照明效果。
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Figure CN224816533U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of optical element technology, specifically to a linear light guide injection molding structure that can achieve no gate residue. Background Technology
[0002] With the rapid advancement of automotive technology, more and more car models are incorporating ambient lighting designs to enhance the technological and premium feel of the car interior. Among these, linear ambient lighting is the most widely used type, and linear light guides are one of its core components.
[0003] Please see Figure 1 and Figure 2 Existing linear light guides typically place the gate in the middle or at the end of the light guide, and have the following drawbacks:
[0004] 1. Gate residue problem: Gates are generally cut manually or by laser. The cut gate is not only prone to problems such as rough and tilted cross-section, but if the residual height is ≥0.2mm, it will cause abnormal local light reflection of the linear light guide.
[0005] 2. Cutting process defects: It is difficult to ensure the consistency of the gate cutting and the roughness of the cut is also difficult to control. When lit, bright spots will be formed, which will destroy the uniformity of the overall light emission of the linear light guide and seriously affect the optical and lighting effects.
[0006] 3. Difficulty in controlling cutting precision: If the laser cutting distance is close, the heat-affected zone is large, and the linear light guide surface is very prone to "air marks" (micro-cracks, carbonization, yellowing); if the cutting distance is far, the residual size of the gate is prone to be too large, resulting in bright spots or light leakage risks on the surface.
[0007] 4. Stress concentration and fracture risk: Stress concentration is prone to occur at the gate location, which may lead to fracture risk at the gate location during production and assembly.
[0008] 5. Restrictions on gate location: To ensure the fluidity of the injection molding process and improve the yield of injection molding, the gate is usually located on the arc-shaped surface of the circumferential sidewall of the linear light guide. However, laser cutting is a straight-line cutting, which causes the thickness in the middle of the gate location to be inconsistent with the thickness on both sides. This not only easily causes local assembly problems, but also has the problem of local bright spot abnormalities.
[0009] 6. High production cost: To avoid bright spots when the gate is lit, black ink or UV glue is usually applied manually to the gate to absorb stray light and solve the problem of bright spots. This not only increases the production process and affects production efficiency, but also increases production cost.
[0010] 7. Limitations on application scope: High-end car models require optical uniformity of over 70% for linear light guides. Existing technologies cannot completely solve the problem of poor uniformity caused by gate residue, resulting in poor yield.
[0011] 8. Optical design limitations: To avoid bright spots when the gate is lit, the light guide teeth / microstructures corresponding to the gate area are usually weakened during the light distribution design stage to reduce the light intensity. This not only imposes greater limitations on optical design, but also places higher requirements on the injection molding process. Utility Model Content
[0012] In view of this, the present invention provides a linear light guide injection molding structure that can achieve no gate residue.
[0013] The technical solution is as follows:
[0014] The first aspect of this application relates to a linear light guide injection molding structure capable of achieving gate-free injection molding, comprising a linear light guide blank, the light guide blank comprising a light guide functional segment, the light guide functional segment comprising a light-emitting unit, at least one end of the light-emitting unit being integrally formed with a light-introducing and light-mixing unit, characterized in that at least one end of the light guide functional segment is integrally formed with a non-functional process segment, the boundary between the non-functional process segment and the light guide functional segment is integrally formed with a cutting mark, and the non-functional process segment is integrally formed with a gate.
[0015] By employing the above-mentioned linear light guide injection molding structure that can achieve no gate residue, the following technical effects have been achieved:
[0016] 1. No gate residue and optical defects: The end of the linear light guide is extended to form a non-functional process section. The gate is set in the non-functional process section. After injection molding, the entire non-functional process section is cut off, avoiding the bright spot problem caused by gate residue in traditional designs. The bright spot elimination rate is 100%, which improves the uniformity of light emission of the linear light guide and improves the optical and lighting effects.
[0017] 2. Improved Cutting Precision: Cutting marks are set at the boundary between the non-functional process section and the optical guide functional section, ensuring extremely high cutting precision regardless of whether manual or laser cutting is used. If laser cutting is used, it can also ensure good cutting consistency, smooth cut, low roughness, no material accumulation, and stable optical performance, thus improving the appearance quality and optical performance of the optical guide. Furthermore, it can be integrated into automated production lines, especially suitable for batch cutting, to achieve more efficient processing.
[0018] 3. Improved cutting efficiency: The cutting process has become much simpler, which not only shortens the cutting time per piece, but also eliminates the need to adjust cutting parameters separately for gates of different curvatures or sizes. This increases the tolerance for errors in cutting parameters and significantly improves the yield rate of cut products, enabling the yield rate to reach over 95%.
[0019] 4. Good versatility: It can be applied not only to linear light guides with various cross-sectional shapes (circular, polygonal, irregular), but also to the manufacture of other precision optical components such as light guide plates, prisms, and lens arrays.
[0020] 5. Environmentally friendly and economical: The gate no longer needs to be blackened, which improves the production efficiency of linear light guides, enhances the environmental friendliness of the manufacturing process, and reduces production costs.
[0021] 6. Eliminate stress concentration and fracture risk: Since the linear light guide finished product does not have a gate position, it effectively solves the problem of fracture risk at the gate position caused by stress concentration during production and assembly. At the same time, since the gate is far away from the light guide functional section during injection molding, the stress concentration phenomenon during injection molding is also reduced, and the warpage deformation is reduced by more than 40%.
[0022] 7. It is the first to add a non-functional process section for injection molding to the linear light guide, so that the light guide functional section can fully serve the optical performance. This breaks through the industry perception that "the gate should be set in the light guide functional section" and creatively proposes the concept of "completely cutting off the non-functional process section after injection molding".
[0023] 8. Increased design freedom: Since the gate position is designed to be "completely cut off from non-functional process sections after injection molding", it is possible to design the gate at any position in the non-functional process section, which improves the flexibility of injection mold design. Moreover, the design of the light guide functional section can completely ignore the gate position, making the shape design of the light guide functional section more free and the optical design more flexible.
[0024] In some embodiments, the cutting mark is a linear rib structure or a linear groove structure formed on the optical guide blank in a circumferential direction.
[0025] In some embodiments, the cutting mark is at least one circumferentially distributed bump or recess structure on the optical guide blank.
[0026] In some embodiments, the gate is integrally formed on the circumferential sidewall or end face of the corresponding non-functional process section.
[0027] In some embodiments, the non-functional process sections are integrally formed with cutting and positioning structures.
[0028] In some embodiments, the cutting positioning structure is:
[0029] Several planar structures formed along the length of the circumferential sidewall of the non-functional process section;
[0030] or,
[0031] Several protrusions are formed on the non-functional process section;
[0032] or,
[0033] Several depressions are formed in the pit structure of the non-functional process section.
[0034] In some embodiments, a plurality of optical guide positioning structures are integrally formed on the optical guide functional segment.
[0035] In some embodiments, the light guide positioning structure is a protrusion integrally formed on the circumferential sidewall of the corresponding light-incoming mixing unit. Attached Figure Description
[0036] Figure 1 This is a schematic diagram of an existing linear light guide with two light-incoming mixing units;
[0037] Figure 2 This is a schematic diagram of an existing linear light guide with one light-incoming mixing unit;
[0038] Figure 3 This is a schematic diagram of the structure of Embodiment 1 of the present utility model;
[0039] Figure 4 This is a schematic diagram of the structure of Embodiment 2 of the present invention;
[0040] Figure 5 This is a schematic diagram of the structure of the linear optical guide finished product after removing the non-functional process sections in Embodiment 1 or Embodiment 2 of this utility model;
[0041] Figure 6 This is a schematic diagram of the structure of Embodiment 3 of this utility model;
[0042] Figure 7 This is a schematic diagram of the structure of the linear optical guide finished product after removing the non-functional process sections in Embodiment 3 of this utility model;
[0043] Figure 8 This is a schematic diagram of the structure of Embodiment 4 of this utility model;
[0044] Figure 9 This is a schematic diagram of the structure of Embodiment 5 of the present invention;
[0045] Figure 10 This is a schematic diagram of the linear optical guide finished product after removing non-functional process sections in Embodiment 4 or Embodiment 5 of this utility model. Detailed Implementation
[0046] The present invention will be further described below with reference to the embodiments and accompanying drawings.
[0047] Example 1:
[0048] like Figure 3 As shown, a linear light guide injection molding structure capable of achieving gate-free residue is provided, comprising a light guide blank 1, which has a linear structure.
[0049] The light guide blank 1 includes a light guide functional segment 11, which is a conventional linear light guide structure. In this embodiment, the light guide functional segment 11 is a linear light guide structure with a light-introducing and light-mixing unit. Specifically, the light guide functional segment 11 includes a light-emitting unit 111 and a light-introducing and light-mixing unit 112 integrally formed at one end of the light-emitting unit 111. The light-emitting unit 111 is a linear structure, and its sidewall has optical patterns 111a distributed along its length. These optical patterns 111a can be common optical patterns such as optical teeth, leather texture, or frosted texture. The end face of the light-introducing and light-mixing unit 112 away from the light-emitting unit 111 is the light-introducing end face. The light emitted by the LED enters the light-introducing and light-mixing unit 112 through the light-introducing end face. The light-introducing and light-mixing unit 112 also has a light-mixing function to eliminate the non-uniformity of light distribution and ensure the softness and consistency of the light emitted by the light-emitting unit 111.
[0050] In this embodiment, a non-functional process segment 12 is integrally formed at the end of the light guide functional segment 11 furthest from the light-incoming mixing unit 112. Cutting marks 121 are integrally formed at the boundary between the non-functional process segment 12 and the light guide functional segment 11. Therefore, by setting the cutting marks 121, extremely high cutting precision can be guaranteed regardless of whether manual or laser cutting is used. If laser cutting is used, good cutting consistency, a smooth cut, low roughness, no material accumulation, and stable optical performance can be guaranteed, improving the appearance quality and optical performance of the light guide. Furthermore, it can be integrated into automated production lines, especially suitable for batch cutting, achieving more efficient processing. The finished product after cutting is as follows: Figure 5 As shown.
[0051] Typically, the cutting mark 121 is formed on the non-functional process segment 12. By using the cutting method of the cutting mark 121, the optical guide functional segment 11 obtained after cutting can be free of defects in appearance and function.
[0052] Furthermore, the non-functional process section 12 is integrally molded with a gate 13. Therefore, after injection molding, the entire non-functional process section 12 is removed, avoiding the bright spot problem caused by gate 13 residue in traditional designs. The bright spot elimination rate is 100%, which improves the uniformity of light emission of the linear light guide and enhances the optical and lighting effects.
[0053] Furthermore, the gate 13 is integrally formed on the circumferential sidewall or end face of the corresponding non-functional process segment 12, that is, the gate 13 can be designed at any position in the non-functional process segment as needed, which improves the flexibility of injection mold design.
[0054] Furthermore, the cutting mark 121 is a linear groove structure formed on the optical guide blank 1 in a circumferential direction. The linear groove structure can surround the optical guide blank 1 in a circle or extend only a short section, as long as it can guide the cutting position.
[0055] In existing technologies, linear light guides are usually not positioned on the tooling, resulting in low cutting precision, difficulty in ensuring cutting consistency, and difficulty in controlling the roughness of the cut, which further exacerbates the problems of appearance and optical performance.
[0056] To address the aforementioned issues, in this embodiment, a cutting and positioning structure 123 is integrally formed on each non-functional process segment 12. Therefore, by providing the cutting and positioning structure 123 on the non-functional process segments 12 (excluding the optical guide functional segment 11), and cooperating with the tooling, it is possible to ensure cutting accuracy, achieve good cutting consistency, and reduce kerf roughness, thereby improving the final product's appearance quality and optical performance. Furthermore, it eliminates the need for a positioning structure on the optical guide functional segment 11, further ensuring the final product's optical performance.
[0057] It should be noted that the cutting positioning structure 123 can take many forms, as long as it can be used with the tooling to achieve reliable positioning. For example, the cutting positioning structure 123 can be several planar structures formed along the length direction on the circumferential sidewall of the non-functional process segment 12, several protruding structures formed on the non-functional process segment 12, or several recessed structures formed on the non-functional process segment 12. Simultaneously, the cutting positioning structure 123 can also be designed on the end face of the non-functional process segment 12.
[0058] Furthermore, in order to further improve the accuracy and reliability of positioning and improve the cutting precision, several light guide positioning structures 113 are integrally formed on the light guide functional segment 11. The light guide positioning structure 113 can also be used as the installation positioning structure of the linear light guide, so as to achieve the effect of dual use in one piece.
[0059] Furthermore, the light guide positioning structure 113 is preferably a protrusion structure integrally formed on the circumferential sidewall of the corresponding light-incoming and light-mixing unit 112. Compared with the groove structure, it can allow more light to enter the light-emitting unit 111, thereby improving the brightness of the light-emitting unit 111.
[0060] Example 2:
[0061] Please see Figure 4A linear light guide injection molding structure capable of achieving gate-free residue is described. Its main structure is identical to that of Example 1, except that the cutting mark 121 is a linear rib structure extending circumferentially on the light guide blank 1. This linear rib structure can encircle the light guide blank 1 completely or extend only a short section, as long as it guides the cutting position. This design improves the fluidity of the fluid flowing towards the light guide functional segment 11 during injection molding, slightly increasing injection molding efficiency.
[0062] The finished product after cutting looks like Figure 5 As shown.
[0063] Example 3:
[0064] Please see Figure 6 A linear light guide injection molding structure capable of achieving gate-free residue is described. Its main structure is identical to that of Example 1, except that the cutting mark 121 is at least one circumferentially distributed protrusion or recess on the light guide blank 1. Typically, only one protrusion or recess is needed for identification. Furthermore, due to the small size of the protrusion or recess, residue is less likely to remain after cutting, further improving the yield of the finished product. Additionally, the non-functional process segment 12 is integrally molded at the end of the light-introducing and mixing unit 112 away from the light guide functional segment 11.
[0065] The finished product after cutting looks like Figure 7 As shown.
[0066] Example 4:
[0067] Please see Figure 8 A linear light guide injection molding structure that can achieve no gate residue is found. Its main structure is exactly the same as that of Example 1, except that the light guide functional segment 11 is a linear light guide structure with two light-introducing and light-mixing units 112.
[0068] Typically, when the length of the light guide functional segment 11 is relatively long, two light-introducing and light-mixing units 112 are provided to ensure the brightness and uniformity of light emission of the light guide functional segment 11. Specifically, the light guide functional segment 11 includes a light-emitting unit 111 and light-introducing and light-mixing units 112 integrally formed at both ends of the light-emitting unit 111.
[0069] In this embodiment, a non-functional process segment 12 is integrally formed at the end of each of the two light-incoming and light-mixing units 112 away from the light-guiding functional segment 11, and a gate 13 is integrally formed on the non-functional process segment 12. This design can improve the efficiency and yield of injection molding.
[0070] The finished product after cutting looks like Figure 10 As shown.
[0071] Example 5:
[0072] Please see Figure 9 A linear light guide injection molding structure that can achieve no gate residue has the same main structure as Example 4, except that: only one of the light-introducing and light-mixing units 112 has a non-functional process section 12 integrally formed at the end away from the light guide functional section 11, while the other light-introducing and light-mixing unit 112 does not have a non-functional process section 12 at the end away from the light guide functional section 11.
[0073] This design, when applied to the injection molding of linear light guides where the length of the light guide functional segment 11 is not very long but the brightness requirement is high, can reduce mold investment costs while ensuring injection molding efficiency and yield.
[0074] The finished product after cutting looks like Figure 10 As shown.
[0075] Finally, it should be noted that the above description is merely a preferred embodiment of the present utility model. Those skilled in the art, under the guidance of the present utility model, can make various similar representations without departing from the spirit and claims of the present utility model, and such modifications all fall within the protection scope of the present utility model.
Claims
1. A linear light guide injection molding structure capable of achieving gate-free residue, comprising a linear light guide blank (1), the light guide blank (1) comprising a light guide functional segment (11), the light guide functional segment (11) comprising a light-emitting unit (111), at least one end of the light-emitting unit (111) being integrally formed with a light-introducing and light-mixing unit (112), characterized in that, At least one end of the light guide functional segment (11) is integrally formed with a non-functional process segment (12), and a cutting mark (121) is integrally formed at the boundary between the non-functional process segment (12) and the light guide functional segment (11), and a gate (13) is integrally formed on the non-functional process segment (12).
2. The linear light guide injection molding structure capable of achieving gate-free residue as described in claim 1, characterized in that, The cutting mark (121) is a linear rib structure or a linear groove structure formed on the optical guide blank (1) extending circumferentially.
3. The linear light guide injection molding structure capable of achieving gate-free residue as described in claim 1, characterized in that, The cutting mark (121) is at least one convex or concave structure distributed circumferentially on the optical guide blank (1).
4. The linear light guide injection molding structure capable of achieving gate-free residue as described in claim 1, characterized in that, The gate (13) is integrally formed on the circumferential sidewall or end face of the corresponding non-functional process section (12).
5. A linear light guide injection molding structure capable of achieving gate-free residue removal, as described in any one of claims 1-4, characterized in that... Each of the non-functional process sections (12) is integrally formed with a cutting and positioning structure (123).
6. The linear light guide injection molding structure capable of achieving gate-free residue as described in claim 5, characterized in that, The cutting positioning structure (123) is as follows: Several planar structures formed along the length direction on the circumferential sidewall of the non-functional process section (12); or, Several protrusions are formed on the non-functional process section (12); or, Several depressions are formed on the non-functional process section (12) of the pit structure.
7. A linear light guide injection molding structure capable of achieving gate-free residue removal, as described in any one of claims 1-4, characterized in that... Several optical guide positioning structures (113) are integrally formed on the optical guide functional segment (11).
8. The linear light guide injection molding structure capable of achieving gate-free residue as described in claim 7, characterized in that, The light guide positioning structure (113) is a protruding structure integrally formed on the circumferential sidewall of the corresponding light-incoming mixing unit (112).