Lens Holder Molding with Elastic Biasing Force
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Solution Overview
Problem
Existing manufacturing methods for image pickup lens units face challenges such as complex assembly processes, increased component count, size limitations, optical defects like ghosts and flares, and dimensional accuracy issues due to tight positioning requirements and resin flow complications.
Innovation Solution
A method involving a two-step molding process where a lens is positioned within a holder member using an elastic biasing force, allowing for direct welding of holder members without additional components, reducing the need for resin paths and minimizing lens deformation, and enabling precise alignment without separate positioning mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a positioning shape is formed in the molds to position the lens, then the lens positioning is achieved, but the positioning shape remains as a visible depression causing optical defects like ghosts and flares
Solution Approach 1:
The patent extracts the harmful positioning shape from the mold by using a positioning member that is separate from the mold structure. The positioning member is inserted into the mold cavity and removed after positioning the lens, so no depression or visible mark remains on the lens surface, eliminating optical defects while maintaining positioning accuracy.
Solution Approach 2:
The patent introduces a positioning member as an intermediary between the mold and the lens. This positioning member temporarily holds the lens in the correct position during molding, then is removed without leaving any trace on the lens, thus mediating the positioning function without causing harmful surface depressions.
2Reliability
If a large holding force is applied to hold the lens and stop in the mold, then the lens and stop are securely positioned, but the optical lens or stop may be deformed or damaged
Solution Approach 1:
The patent applies holding force locally through specifically designed holding portions on the lens and corresponding recesses in the positioning member, rather than applying force across the entire lens surface. This localized approach secures the lens and stop firmly in position while concentrating the force in safe areas that will not cause deformation or damage to the optical surfaces.
3Strength
If the holder body and cover are connected with additional components, then the connection strength is improved, but the number of molded components increases and the molding step becomes complicated
Solution Approach 1:
The patent merges the holder body and cover into a single integrated molded component. The mold cavity is designed to form both the holder body and cover in one molding operation, with the lens already positioned inside. This eliminates the need for separate components and additional joining steps, reducing complexity while maintaining connection strength through the integrated structure.
4Ease of manufacture
If a resin flow path is created for joining components, then the joining is achieved, but it is very difficult to ensure filling properties and joint strength of a thin-wall holder
Solution Approach 1:
The patent merges the holder body and cover into a single integrated component molded in one step, eliminating the need for resin flow paths for joining separate components. This approach avoids the difficulties of ensuring proper filling and joint strength in thin-wall structures, as no joining operation is required.
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 approach simplifies the assembly process, reduces component count, minimizes optical defects, and enhances dimensional accuracy, resulting in a smaller, more reliable image pickup lens unit with improved manufacturing efficiency.
Implementation Method 1
bringing the lens and the mold in contact by an elastic biasing force at the time of fixing the lens
Implementation Method 2
filling in a resin material in a mold and then molding the first holder member
Data Source
AI summary
Method for manufacturing an image pickup lens unit. In the second molding step, by performing additional molding with respect to a first holder member 20 in which a lens 10 has been inserted, the separation of the lens 10 can be prevented and, at the same time, a second holder member 30 welded to the first holder member 20 can be molded. Therefore, molding of the second holder member 30 and the process of joining the second holder member with the first holder member 20 can be performed together. Additionally, when the lens 10 is fixed from the side of a third molding portion 63 of a second mold 52, the lens 10 and the third molding portion 63 are brought in contact by an elastic biasing force, thereby reducing breakage or deformation of the lens 10.