Lens Fabrication Mold with Balancing Rings for Pressure Uniformity
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Solution Overview
Problem
Existing molds for lens fabrication result in uneven pressure distribution, leading to inconsistent lens quality and appearance due to the array arrangement of upper and lower molding parts, causing significant differences between lenses formed in inner and outer mold cavities.
Innovation Solution
A mold design featuring first and second molds with specific gap configurations and balancing rings to ensure consistent lens molding pressure, including first and second gaps with varying thickness gradients and balancing rings to facilitate transitions, allowing for precise adjustment of molding pressure and cycle consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple upper molding parts and lower molding parts are arranged in an array, then production efficiency is improved, but pressure distribution becomes uneven causing inconsistent lens quality
Solution Approach 1:
The patent introduces balancing rings at specific locations (inner periphery of outer molding parts and outer periphery of inner molding parts) to provide localized pressure compensation. This allows different regions of the mold to have different functional characteristics - the array arrangement maintains high productivity while the balancing rings ensure uniform pressure distribution for consistent lens quality.
Solution Approach 2:
The balancing rings act as intermediary structures between the molding parts and the sheet material. These intermediate components redistribute the molding pressure from the array-arranged molding parts to achieve uniform pressure distribution across all lens cavities, resolving the contradiction between productivity and quality consistency.
2Ease of manufacture
If upper and lower molds come together to extrude sheet material, then lens formation is achieved, but pressure at center and edge becomes uneven
Solution Approach 1:
The balancing rings are strategically positioned at the inner periphery of outer molding parts and outer periphery of inner molding parts to provide localized pressure compensation. This local modification ensures uniform pressure distribution across different regions (center and edge) while maintaining the overall lens formation capability.
Solution Approach 2:
The balancing rings modify the pressure distribution parameter by creating a gradient in the molding force. The rings are designed with specific dimensions and positions that transform the uneven pressure distribution into a uniform pressure field across all mold cavities.
3Productivity
If array arrangement of molding parts is used, then manufacturing speed increases, but appearance quality of lenses deteriorates
Solution Approach 1:
The balancing rings serve as intermediary structures that mediate between the high-speed array arrangement and the quality requirement. They ensure that even though multiple lenses are formed simultaneously in an array, each lens receives uniform pressure distribution, maintaining high appearance quality while preserving manufacturing speed.
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
The solution achieves high-quality, consistent lens production with improved production efficiency by ensuring uniform pressure distribution and reducing molding cycle time.
Implementation Method 1
the first balancing ring is configured to facilitate an inclined transition between the outer peripheral edge of the second molding part and the side of the first mold body close to the second mold. The second balance ring is configured to facilitate a transition between the outer peripheral edge of the fourth molding part and the side of the second mold body close to the first mold
Data Source
AI summary
A mold and a method for fabricating a lens are provided, for shaping the lens. The mold includes a first mold and a second mold matching the first mold. The first mold includes a first mold body, multiple first molding parts with an arc-shaped surface formed by a side of the first mold body close to the second mold, annular second molding parts respectively formed by outer peripherals of the first molding part and annular first balancing rings formed by outer peripherals of the second molding parts. The second mold includes a second mold body, multiple annular third molding parts formed on a side of the second mold body close to the first mold, annular fourth molding parts respectively formed around the outer peripherals of the third molding parts and annular second balancing rings formed by the outer peripherals of the fourth molding parts.