Insert core position adjusting device capable of correcting central axis error
The insert core position adjustment device corrects central axis errors in microlens arrays by aligning lens surfaces, improving productivity and optical performance in automotive headlamps.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- A TECH SOLUTION
- Filing Date
- 2025-01-10
- Publication Date
- 2026-07-02
AI Technical Summary
The alignment errors between the central axes of individual lenses in microlens arrays, resulting from separate injection molding and bonding processes, lead to decreased optical performance and reduced product yield in automotive headlamps.
An insert core position adjustment device that integrates the first and second lens surfaces through a position adjustment unit, comprising a first insert core, a second insert core, and a position adjustment unit, which aligns the center axes of the lens surfaces using screws and block stoppers to correct optical axis errors.
Enhances productivity, increases yield, and improves optical performance by accurately aligning the lens surfaces during the injection molding process.
Smart Images
Figure KR2025000580_02072026_PF_FP_ABST
Abstract
Description
Insert core position adjustment device capable of center axis error correction
[0001] The present invention relates to an insert core position adjustment device capable of correcting a central axis error, and more specifically, to an insert core position adjustment device capable of correcting a central axis error that can provide the effects of increased productivity, increased yield, and improved optical performance by integrally injection molding a first lens surface and a second lens surface of a lens and adjusting the position of the insert core in response to the optical axis error of a first lens product.
[0002] A microlens array (MLA) is a type of lens in which multiple individual lenses are arranged. The demand for microlens arrays is gradually increasing in optical systems such as beam projectors, optical communications, and LiDAR for the purpose of diffusing and focusing light.
[0003] FIG. 1 is a side cross-sectional view illustrating the structure of a lamp (1) to which a micro-lens array is applied. Referring to FIG. 1, a light source (3) that generates and emits light is mounted on a PCB (2), and a collimator lens (4) is positioned in front of the light source (3) to convert light incident from the light source (3) into parallel light. In addition, a micro-lens module (5) including a plurality of micro-lenses is provided in front of the collimator lens (4). The micro-lens module (5) is provided facing the collimator (4) and includes an incident lens array (5a) into which light from the light source (3) is incident, and an output lens array (5b) provided in front of the incident lens array (5a) and which receives the light incident on the incident lens array (5a) and emits it outward. As shown in FIG. 1, a plurality of micro-lenses are formed convexly protruding on the surface of the incident lens array (5a) facing the collimator (3), and a plurality of micro-lenses are formed convexly protruding on the exit side surface of the exit lens array (5b).
[0004] As light incident on multiple individual micro-lenses constituting a micro-lens array travels only in a specific direction, it can form a specific pattern on the road surface through an optical system with a size of approximately 10 mm. Therefore, micro-lens arrays are recently being used as a configuration to perform the welcome light function in automobiles.
[0005] Generally, lighting installed in vehicles, such as headlamps, focuses on directing light forward. Therefore, in the past, the focus was on developing technologies to ensure light concentration and diffusion. However, recently, technologies are being developed to emphasize the design aspects of lighting. Consequently, attempts to apply micro-lens arrays to automotive headlamps have recently emerged.
[0006] However, such microlens arrays are formed by injection molding the incident lens array and the exit lens array separately and then integrating them through a bonding process. This bonding process requires high precision, and there is a problem in that alignment errors occur between the central axes of the individual lenses constituting the incident array and the individual lenses constituting the exit lens array during the bonding process, leading to a decrease in optical performance as well as a drop in product yield.
[0007] Accordingly, the objective of the present invention is to provide an insert core position adjustment device capable of correcting center axis error, which can provide the effects of increased productivity, increased yield, and improved optical performance by integrally injection molding the first lens surface and the second lens surface of the lens and adjusting the position of the insert core in response to the optical axis error of the initial lens product, thereby solving the aforementioned conventional problems.
[0008] The above objective is achieved by an insert core position adjustment device capable of correcting a center axis error, characterized in that it comprises: a first insert core supported by a first mold and having a first cavity formed therein for forming a first lens surface on one side of a lens; a second insert core formed therein for forming a second lens surface on the other side of a lens and positioned to face the first insert core while supported by a second mold; and a position adjustment unit capable of adjusting the relative position of the first insert core to the second insert core on the first mold to align the center axis of the first lens surface with the center axis of the second lens surface.
[0009] Here, it is preferable that the position adjustment unit includes a first adjustment unit for adjusting the left-right position of the first insert core and a second adjustment unit for adjusting the front-back position of the first insert core.
[0010] Additionally, it is preferable that the first adjustment unit and the second adjustment unit include a screw that is screw-coupled to a first mold to adjust the left-right or front-back position of the first insert core, and a pressure block that is in close contact with the outer surface of the first insert core and transmits the pressure applied by the screw to the first insert core.
[0011] In addition, the position adjustment unit further includes block stoppers positioned at the front, rear, left, and right sides of the receiving space opening of the first mold, and it is preferable that a locking projection into which the block stoppers can be inserted is formed on the outer surfaces in the front, rear, left, and right directions of the first insert core.
[0012] In addition, it is preferable that one of the block stoppers spaced apart from the left and right is positioned between the first insert core and the pressure block of the first adjustment part, and one of the block stoppers spaced apart from the front and back is positioned between the second insert core and the pressure block of the second adjustment part.
[0013] In addition, it is preferable that any one of the block stoppers spaced apart from the left and right and any one of the block stoppers spaced apart from the front and back each provide a reference surface for supporting the first insert core and are detachably fixed to the first mold frame by means of a fastening member.
[0014] In addition, it is desirable that the block stopper providing the above reference plane be able to adjust the position of the reference plane in response to the error correction amount.
[0015] In addition, it is desirable that the block stopper providing the above reference plane be able to adjust the inclination of the reference plane in response to the error correction inclination.
[0016] According to the present invention, an insert core position adjustment device capable of correcting a center axis error is provided, which can provide the effects of increased productivity, increased yield, and improved optical performance by integrally injection molding a first lens surface and a second lens surface of a lens and adjusting the position of the insert core in response to an optical axis error of a first lens product.
[0017] FIG. 1 is a side cross-sectional view illustrating the structure of a lamp to which a conventional micro-lens array is applied.
[0018] FIG. 2 is a perspective view of an insert core position adjustment device capable of correcting center axis error according to the present invention.
[0019] FIG. 3 is a plan view of the second mold frame shown in FIG. 2,
[0020] FIG. 4 is a bottom perspective view of the first mold frame shown in FIG. 2,
[0021] Fig. 5 is an exploded perspective view of the first mold frame shown in Fig. 4.
[0022] FIG. 6 is a planar cross-sectional view of a first mold according to an insert core position adjustment device capable of correcting center axis error of the present invention,
[0023] FIG. 7 is a cross-sectional view along line A-A' of FIG. 6,
[0024] FIG. 8 is a cross-sectional view along line B-B' of FIG. 6,
[0025] FIGS. 9 and 10 are operational diagrams of a first adjustment unit according to an insert core position adjustment device capable of correcting center axis error according to the present invention, and
[0026] FIG. 11 is an operational diagram showing the tilt correction state according to the insert core position adjustment device capable of correcting the center axis error of the present invention.
[0027] Before proceeding with the explanation, in various embodiments, components having the same configuration are denoted by the same reference numerals and are described representatively in the first embodiment, while in other embodiments, configurations different from the first embodiment are described.
[0028] Hereinafter, an insert core position adjustment device capable of correcting center axis error according to the first embodiment of the present invention will be described in detail with reference to the attached drawings.
[0029] Among the attached drawings, FIG. 2 is a perspective view of an insert core position adjustment device capable of correcting the center axis error of the present invention, FIG. 3 is a plan view of the second mold frame shown in FIG. 2, FIG. 4 is a bottom perspective view of the first mold frame shown in FIG. 2, and FIG. 5 is an exploded perspective view of the first mold frame shown in FIG. 4.
[0030] The insert core position adjustment device capable of correcting the center axis error of the present invention as illustrated in the drawing above includes a first insert core (110), a second insert core (120), a position adjustment unit, and a block stopper.
[0031] The first insert core (110) has a first cavity (111) formed on the surface facing the second insert core (120) to form a first lens surface on one side of the lens, and is supported by a first mold (M1).
[0032] The second insert core (120) has a second cavity (121) formed on the surface facing the first insert core (110) to form a second lens surface on one side of the lens, and is supported by a second mold (M2).
[0033] The first mold frame (M1) may be a movable mold that is positioned above the second mold frame (M2) and moves up and down, and the second mold frame (M2) may be a fixed mold that is positioned below the first mold frame (M1) and has a fixed position.
[0034] The first insert core (110) and the second insert core (120) can be assembled to the first mold frame (M1) and the second mold frame (M2), respectively, while being supported by the mold core (MC). When the mold core (MC) is applied, the receiving space (M1a) into which the first insert core (110) or the second insert core (120) is inserted can be understood as being formed in the mold core (MC).
[0035] Additionally, the second mold (M2) may be provided with an eject pin for separating the injection-completed lens from the second cavity (121) of the second insert core (120) and a lifting mechanism for raising the eject pin.
[0036] The above position adjustment unit is configured to adjust the relative position of the first insert core (110) to the second insert core (120) on the first mold (M1) in order to align the center axis of the first lens surface with the center axis of the second lens surface.
[0037] In this embodiment, the position adjustment unit is described as adjusting the position of the first insert core (110) in the first mold (M1) as an example, but it is not limited thereto, and it may also be possible to adjust the position of the second insert core (120) in the second mold (M2) as needed.
[0038] The position adjustment unit includes a first adjustment unit (130) capable of adjusting the left and right (X-axis direction of the drawing) position of the first insert core (110) on the first mold (M1), and a second adjustment unit (140) capable of adjusting the front and rear (Y-axis direction of the drawing) position of the first insert core (110).
[0039] Specifically, the first adjustment unit (130) includes a fixing block (131) that has a through hole formed in the X-axis direction and is fixed to the first mold (M1), a screw (132) that is screw-coupled to the through hole of the fixing block (131) to adjust the left / right or front / back position of the first insert core (110), a pressure block (133) disposed between the screw (132) and the first insert core (110), and a guide block (134) that guides the movement of the pressure block (133) in the X-axis direction. Meanwhile, a head portion may be provided at the rear end of the screw (132).
[0040] The second adjustment unit (140) includes a fixed block (141), a screw (142), a pressure block (143), and a guide block (144). Since it has the same configuration as the first adjustment unit (130) except for the difference in that it is arranged in the Y-axis direction, a detailed description thereof is omitted.
[0041] The block stopper is fixed to the front, back, left, and right sides of the opening of the receiving space (M1a) of the first mold (M1) into which the first insert core (110) is inserted, respectively, thereby stably fixing the position of the first insert core (110) within the receiving space (M1a).
[0042] A support groove (M1b) into which the block stopper can be inserted is formed in the first mold (M1), and a catch projection (112) into which the block stopper can be seated and supported is formed in the first insert core (110). At this time, it is preferable that the width of the catch projection (112) be set to be relatively wider than the width of the block stopper.
[0043] The above block stopper may be divided into a first-1 stopper (151) in contact with the pressure block (133) of the first control unit (130), a first-2 stopper (152) facing the first-1 stopper (151), a second-1 stopper (153) in contact with the pressure block (143) of the second control unit (140), and a second-2 stopper (154) facing the second-1 stopper (153).
[0044] A through hole through which a fastening member can pass is formed in each of the 1-1 stopper (151), 1-2 stopper (152), 2-1 stopper (153), and 2-2 stopper (154), and the through hole formed in the 1-1 stopper (151) and 2-1 stopper (153) may be formed in the shape of an elongated hole.
[0045] The first-2 stopper (152) provides a reference plane for determining the left-right position of the first insert core (110) opposite the first-1 stopper (151), and the second-2 stopper (154) provides a reference plane for determining the up-down position of the first insert core (110) opposite the second-1 stopper (153).
[0046] Accordingly, with the fixing force of the fastening member fixing the first-1 stopper (151) and the second-1 stopper (153) set loosely, the first adjustment part (130) and the second adjustment part (140) are each moved in the forward direction so that the first-1 stopper (151) and the second-1 stopper (153) each press the first insert core (110) to be in close contact with the first-1 stopper (151) and the second-2 stopper (154), and then the fastening member penetrating the first-1 stopper (151) and the second-1 stopper (153) is tightened to firmly fix the position of the first-1 stopper (151) and the second-1 stopper (153).
[0047]
[0048] From now on, the operation of the first embodiment of the insert core position adjustment device capable of correcting the center axis error described above will be explained.
[0049] Among the attached drawings, FIG. 6 is a plan cross-sectional view of a first mold according to the insert core position adjustment device capable of correcting the center axis error of the present invention, FIG. 7 is a cross-sectional view along line A-A' of FIG. 6, FIG. 8 is a cross-sectional view along line B-B' of FIG. 6, FIG. 9 and FIG. 10 are operational diagrams of a first adjustment part according to the insert core position adjustment device capable of correcting the center axis error of the present invention, and FIG. 11 is an operational diagram showing the tilt correction state according to the insert core position adjustment device capable of correcting the center axis error of the present invention.
[0050] The first insert core (110) is received within a receiving space (M1a) formed in the first mold (M1) (or mold core (MC)), and its left and right sides (X-axis) are supported by the first-1 stopper (151) and the first-2 stopper (152), and its front and rear sides (Y-axis) are supported by the second-1 stopper (153) and the second-2 stopper (154), thereby determining its position on the XY plane.
[0051] At this time, the first-2 stopper (152) and the second-2 stopper (154) are fixed on the first mold frame (M1) by a fastening member to provide a reference plane for determining the X-axis and Y-axis positions of the first insert core (110).
[0052] Additionally, the X-axis position of the 1-1 stopper (151) can be adjusted by the 1st adjustment unit (130), and the Y-axis position of the 2-1 stopper (153) can be adjusted by the 2nd adjustment unit (140), and after the position is determined, it can be firmly fixed on the 1st mold (M1) by a fastening member.
[0053] With the first insert core (110) fixed to the first mold (M1) as described above, the first mold (M1) and the second mold (M2) are joined together as shown in FIG. 9 to bring the first insert core (110) and the second insert core (120) into close contact, and then molten resin is injected into the first cavity (111) and the second cavity (121) to injection mold the lens. In the drawings of this embodiment, the first cavity (111) and the second cavity (121) are illustrated as having a concave arc shape to enhance understanding of the invention, but are not limited thereto.
[0054] Afterward, the center axis error between the first lens surface and the second lens surface of the injection-molded lens prototype is measured, and the X-axis position of the first insert core (110) is corrected using the first adjustment unit (130) in response to the measured error, and the Y-axis position of the first insert core (110) is corrected using the second adjustment unit (140), thereby aligning the center axis of the second lens surface and the first lens surface.
[0055] For example, as shown in FIG. 9, if the first cavity (111) of the first insert core (110) and the second cavity (121) of the second insert core (120) are arranged so as to be offset from each other in the X-axis direction, an error may occur in the center axis of the first lens surface and the second lens surface of the injection-molded lens prototype with respect to the X-axis direction. In such a case, as shown in FIG. 10, the fastening member that fastens the first-1 stopper (151) is loosened to release the fixing force, and the first adjustment part (130) is operated to move the first-1 stopper (151) forward or backward, thereby adjusting the left and right position of the first insert core (110). After the operation of the first adjustment part (130) is completed, the fastening member is tightened again to firmly fix the first-1 stopper (151) to the first mold frame (M1).
[0056] Since the screw (132) of the first adjustment unit (130) is configured to advance by forward axial rotation and retract by reverse axial rotation, the axial position may not be arbitrarily changed by an axial external force, such as a reaction force transmitted from the first insert core (110). Therefore, by forming the fastening hole of the first-1 stopper (151) that determines the position of the first insert core (110) as described above in the shape of an elongated hole, position adjustment is possible, while preventing the set position of the first-1 stopper (151) supported by the first adjustment unit (130) from being arbitrarily changed by an external force.
[0057] Meanwhile, the first and second stoppers (152) can be configured to adjust the reference plane position in response to the center axis error between the first lens surface and the second lens surface of the lens prototype.
[0058] For example, the first-2 stopper (152) may be provided with multiple reference surface protrusion lengths of different lengths, and the position of the reference surface may be adjusted by selecting one of the first-2 stoppers, which has a reference surface corresponding to the center axis error between the first lens surface and the second lens surface of the lens prototype, and fixing it to the first mold (M1). In addition, the position of the reference surface of the first-2 stopper (152) may be adjusted by machining the reference surface corresponding to the center axis error between the first lens surface and the second lens surface of the lens prototype.
[0059] The first and second stoppers (152) can be configured to adjust the inclination of the reference plane in response to the inclination error between the first lens surface and the second lens surface of the lens prototype.
[0060] For example, as illustrated in FIG. 11, the first-2 stopper (152) may be provided with a plurality of reference planes having different inclinations, and the inclination of the reference plane may be adjusted by selecting one of the first-2 stoppers, which has a reference plane inclination corresponding to the inclination error between the first lens surface and the second lens surface of the lens prototype, and fixing it to the first mold (M1). In addition, the first-2 stopper (152) may also adjust the inclination of the reference plane by machining the reference plane to correspond to the center axis error between the first lens surface and the second lens surface of the lens prototype.
[0061] At this time, it would be preferable for the first-1 stopper (151) and the second-1 stopper (153) to be configured such that the contact portion with the first insert core (110) is formed as an arc-shaped protrusion to enable point contact.
[0062]
[0063] The scope of the present invention is not limited to the embodiments described above but may be implemented in various forms of embodiments within the scope of the appended claims. It is deemed that the scope of the claims of the present invention includes various modifications that are possible by anyone with ordinary knowledge in the technical field to which the invention pertains, without departing from the essence of the invention claimed in the claims.
Claims
1. A first insert core supported by a first mold and having a first cavity formed therein for forming a first lens surface on one side of the lens; A second insert core having a second cavity formed to form a second lens surface on the other side of the lens and positioned to face the first insert core while supported by a second mold frame; and An insert core position adjustment device capable of correcting center axis errors, characterized by including: a position adjustment unit capable of adjusting the relative position of the first insert core with respect to the second insert core on the first mold to align the center axis of the first lens surface with the center axis of the second lens surface.
2. In Paragraph 1, An insert core position adjustment device capable of center axis error correction, characterized in that the above position adjustment unit includes a first adjustment unit for adjusting the left-right position of the first insert core and a second adjustment unit for adjusting the front-back position of the first insert core.
3. In Paragraph 2, An insert core position adjustment device capable of correcting center axis error, characterized in that the first adjustment unit and the second adjustment unit include a screw that is screw-coupled to a first mold to adjust the left-right or front-back position of the first insert core, and a pressure block that is in close contact with the outer surface of the first insert core and transmits the pressure applied by the screw to the first insert core.
4. In Paragraph 3, The above position adjustment unit further includes block stoppers respectively positioned at the front, rear, left, and right sides of the receiving space opening of the first mold frame, and An insert core position adjustment device capable of correcting center axis error, characterized in that a locking projection into which the block stopper can be inserted is formed on each of the front, rear, left, and right outer surfaces of the first insert core.
5. In Paragraph 4, An insert core position adjustment device capable of correcting a central axis error, characterized in that one of the block stoppers spaced apart left and right is positioned between the first insert core and the pressure block of the first adjustment unit, and one of the block stoppers spaced apart front and back is positioned between the second insert core and the pressure block of the second adjustment unit.
6. In Paragraph 4, An insert core position adjustment device capable of correcting a center axis error, characterized in that one of the block stoppers spaced apart left and right and one of the block stoppers spaced apart front and rear each provide a reference surface for supporting a first insert core and are detachably fixed to the first mold frame by a fastening member.
7. In Paragraph 6, An insert core position adjustment device capable of center axis error correction, characterized in that the block stopper providing the above reference plane can adjust the position of the reference plane in correspondence with the error correction amount.
8. In Paragraph 6, An insert core position adjustment device capable of center axis error correction, characterized in that the block stopper providing the above reference plane can adjust the inclination of the reference plane in correspondence with the error correction inclination.