Composite Lens Resin Marker for Mold Alignment
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Solution Overview
Problem
Existing methods for producing composite lenses face challenges in accurately aligning the mold with the base lens due to the difficulty in measuring the resin marker, which is often unclear and insufficiently filled, leading to aberrations and reduced optical performance.
Innovation Solution
The composite lens design features a resin lens with surfaces outside the optically effective diameter, including an inclined surface, a perpendicular plane, and a protuberant edge, forming a sharp edge that serves as a clear resin marker for alignment, allowing for precise mold alignment and enhanced optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a resin marker is formed in the center of the mold surface, then alignment between the base lens and mold can be achieved, but the resin marker becomes unclear and difficult to measure
Solution Approach 1:
The resin marker is extracted from the center of the mold surface and relocated to the peripheral region. This extraction from the problematic center location resolves the measurement difficulty while preserving the alignment function. The marker is now formed at a location where resin naturally accumulates during molding, ensuring both clarity and measurability.
Solution Approach 2:
The resin marker is designed with specific three-dimensional geometric features including inclined surfaces and sharp edges. These dimensional characteristics create high contrast and clear boundaries that are easily detectable by measuring microscopes, transforming an invisible flat feature into a clearly visible three-dimensional structure.
2Ease of manufacture
If the resin marker is formed with a curved surface, then it can be created during molding, but the marker becomes unclear when viewed from the optical axis direction
Solution Approach 1:
The resin marker incorporates asymmetric geometric features including inclined surfaces and sharp edges rather than symmetric curved surfaces. This asymmetry creates distinct directional features that are clearly visible from the optical axis direction, while still being formable through standard molding processes that can create non-symmetric peripheral structures.
Solution Approach 2:
While avoiding purely curved surfaces, the invention uses controlled curvature in specific regions (such as the connecting portions between inclined surfaces) to ensure the marker remains formable by molding. The curvature is applied selectively to create smooth transitions while maintaining the overall sharp, angular features needed for visibility.
3Productivity
If the mold alignment is not accurate, then production efficiency is maintained, but optical performance deteriorates due to aberrations
Solution Approach 1:
The resin marker automatically forms during the normal molding process without requiring separate alignment operations. The marker leverages the natural resin flow and accumulation patterns during molding, making the alignment reference self-generating and eliminating time-consuming manual alignment steps while ensuring consistent optical performance.
Solution Approach 2:
The resin marker creates optical contrast through geometric features rather than material composition changes. The sharp edges and inclined surfaces reflect and refract light differently, creating visual contrast that can be easily detected by measuring instruments, enabling rapid verification of alignment quality without adding production steps.
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 design facilitates accurate alignment of the mold to the base lens, resulting in high-productivity and high-precision composite lenses with improved optical performance by providing a clear and easily identifiable resin marker, reducing misalignment and enhancing the production of high-quality optical equipment.
Implementation Method 1
a resin lens having an aspheric shape is produced on the surface of the spherical lens, so as to produce a composite lens functioning as an aspheric lens
Data Source
AI summary
A composite lens of the present invention has a base lens and a resin lens placed on the base lens. The resin lens has, in an area outside an optically effective diameter, a first surface, a second surface that is adjacent to the first surface, and a third surface that is adjacent to the second surface in sequence from an optical axis to an outer circumference. The first surface has an inclined surface that becomes higher from the outer circumference toward the optical axis, and the inclined surface is connected to the second surface. The second surface has a plane that is substantially perpendicular to the optical axis, and the substantially perpendicular plane is connected to the first plane. The third surface has an inclined surface that becomes lower from an inner circumference toward the outer circumference.