Co-molded Optical Components with Integrated Carrier
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Solution Overview
Problem
Current methods for producing optical components, such as lenses for semiconductor light sources, are inefficient and costly, particularly in high batch numbers, as they require individual insertion of optical elements into separate frame parts.
Innovation Solution
A method involving an initial carrier with cutouts, where a molding process forms transparent optical molded parts within the cutouts, and the carrier is singulated to produce separate optical components with a carrier and molded part, using a UV-curing molding compound and tool parts to create beam-shaping surfaces and structures like Fresnel lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual insertion of optical elements into separate frame parts is used, then assembly precision can be maintained, but production cost and complexity increase significantly
Solution Approach 1:
The patent combines the frame part and optical element into a single integrated component produced through co-molding. The frame carrier and optical element are molded together in one process, eliminating the need for separate insertion and assembly steps. This merging of previously separate components resolves the contradiction by reducing both production cost and assembly complexity while maintaining manufacturing precision.
Solution Approach 2:
The frame carrier is designed to serve multiple functions: it provides structural support, defines the housing for the optical element, and integrates directly with the optical element through co-molding. This multi-functionality eliminates the need for separate assembly operations, thereby reducing production complexity and cost while maintaining the precision required for optical applications.
2Productivity
If individual production of optical components is used, then component quality can be maintained, but productivity decreases for high batch numbers
Solution Approach 1:
The molding process is segmented into distinct cavities within the mold, allowing multiple optical components to be produced simultaneously in parallel. Each cavity maintains independent molding conditions and precision control, ensuring that component quality is maintained while productivity increases through batch production of multiple units in a single molding cycle.
Solution Approach 2:
The patent merges multiple production operations into a single co-molding process that produces both the frame carrier and optical element simultaneously. This integration maintains manufacturing precision through controlled molding parameters while dramatically increasing productivity by eliminating sequential assembly steps and enabling high batch number production in one operation.
3Productivity
If transparent plastic material with optically transmissive side walls is used, then optical performance is improved, but production efficiency decreases
Solution Approach 1:
The co-molding process merges the formation of the frame carrier and optical element into a single operation, significantly improving production efficiency. The optical elements maintain their required optical performance through precise molding control, while the transparent plastic material with optically transmissive side walls is integrated directly into the molded component, eliminating post-production assembly steps and enhancing both efficiency and reliability.
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 enables economical production of optical components with beam-shaping capabilities, reducing production costs and complexity by forming multiple components in parallel, with the ability to produce high batch numbers efficiently.
Implementation Method 1
a molding compound is introduced into the cutouts of the initial carrier and the molding compound is molded and cured
Data Source
AI summary
A method of producing optical components includes providing an initial carrier including cutouts; carrying out a molding process to form transparent optical molded parts arranged in the cutouts of the initial carrier, wherein a molding compound is introduced into the cutouts of the initial carrier and the molding compound is molded and cured; and singulating the initial carrier including the optical molded parts so that separate optical components are formed that respectively include a carrier produced from the initial carrier and including a cutout, and an optical molded part arranged in the cutout.