Aspherical Prism Integration for Uniform High-Throughput Processing
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Solution Overview
Problem
The preparation method of three-in-one prisms in existing technologies results in a long preparation cycle, low machining efficiency, and large fluctuations in dimensional accuracy, making it difficult to achieve uniformity.
Innovation Solution
An aspherical prism preparation method involving hot press molding to integrate lens and prism formation, followed by sequential grinding, polishing, chamfering, coating, and ink application based on the same datum, allowing simultaneous processing of multiple prisms in a single operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lenses and prisms are processed separately using different equipment with individual grinding, polishing, coating, and ink application processes, then each component can be manufactured with specialized equipment, but the preparation cycle becomes long, machining efficiency becomes low, and dimensional accuracy fluctuations increase
Solution Approach 1:
The patent combines the lens and prism into a single integrated component that is processed as one unit. The grinding, polishing, coating, and ink application processes are performed on the integrated component in a single production line, eliminating the need for separate processing of lens and prism. This merging of components and processes directly resolves the contradiction by reducing the preparation cycle and improving machining efficiency while maintaining manufacturing flexibility through the integrated design.
2Manufacturing precision
If lenses and prisms are assembled using adhesive bonding or support bracket assembly with high requirements for fit clearance and assembly accuracy, then the optical performance can be maintained, but the assembly complexity increases and production time is extended
Solution Approach 1:
The patent integrates the lens and prism into a single monolithic component with unified optical surfaces. The incident surface (originally the lens surface) and reflective surface (originally the prism surface) are formed as continuous surfaces on the same substrate. This eliminates the need for assembly operations entirely, removing adhesive bonding and support bracket requirements, while maintaining optical performance through the continuous optical path. The complexity reduction is achieved by eliminating multiple assembly steps and the associated precision requirements for fit clearance and alignment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces the preparation cycle, enhances processing efficiency, minimizes dimensional fluctuations, and ensures structural accuracy by integrating processing stages, eliminating assembly errors.
Implementation Method 1
molding a lens configured to form an incident surface and a prism integrally using a hot press molding method
Implementation Method 2
laser cutting or wire cutting is used for cutting
Implementation Method 3
performing a first grinding and a first polishing on a right-angled surface
Implementation Method 4
performing the second polishing on the machined curved surface structure
Implementation Method 5
coating the strip glass after being chamfering
Data Source
AI summary
The present application provides an aspherical prism and a preparation method thereof, and the method including: S1, molding a lens and a prism integrally using a hot press molding method to obtain a molding body glass; S2, cutting the molding body glass into a strip glass; S3, performing a first grinding and a first polishing on a right-angled surface; S4, machining a curved surface structure on the right-angled surface; S5, performing a second polishing on the machined curved surface structure; S6, machining an reflective surface; S7, chamfering edges of the strip glass; S8, coating the strip glass after being chamfering; and S9, cutting the coated strip glass into individual aspherical prisms. The preparation method can not only process a plurality of aspherical prisms at one time, but also reduces the preparation cycle, improves processing efficiency, and minimizes dimensional fluctuations to achieve uniformity.