Lens Molding Device With Removable Injector for Bond Integrity
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Solution Overview
Problem
Existing methods for manufacturing lenses for optoelectronic components face issues with the deterioration of the bond between the molded part and the transparent plate during demolding, leading to reduced efficiency and deformation of the lenses.
Innovation Solution
A molding device with a removable injector that allows controlled breaking of the molding bead, maintaining the connection between the transparent plate and the molded part by ensuring the injector can be removed while the transparent plate remains fixed to the molding element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the injector is fixed and integrated with the molding element, then the injection process is stable and reliable, but the molding bead cannot be broken before demolding, causing deterioration of the bond between the molded part and transparent plate
Solution Approach 1:
The molding device is segmented into separable components: the injector is made detachable from the molding element, allowing independent removal of the injector while keeping the molding element and transparent plate assembly intact. This segmentation enables the molding bead to be broken at the injector interface without compromising the bond between the molded part and transparent plate.
Solution Approach 2:
The injector is removed before the demolding operation to preliminarily break the molding bead connection. This preliminary action prevents the molding bead from being torn during subsequent demolding, thereby preserving the bond integrity between the molded part and transparent plate.
2Ease of manufacture
If the molding bead is broken during demolding, then the molded part can be removed from the mold, but the bond between the molded part and transparent plate deteriorates
Solution Approach 1:
The injector is extracted as a separate removable component from the molding assembly. By removing the injector, the molding bead is naturally broken at the injector interface rather than being torn during demolding. This extraction approach ensures that the bond between the molded part and transparent plate remains intact while still enabling demolding.
Solution Approach 2:
The injector removal is performed as a preliminary step before demolding to break the molding bead connection. This preliminary breaking action prevents harmful tearing during the actual demolding process, thereby maintaining both ease of manufacture and manufacturing precision.
3Device complexity
If a fixed injector is used, then the device structure is simple, but the molding bead cannot be controlled to break at the right moment, causing bond deterioration
Solution Approach 1:
The injector structure is made dynamic and adjustable rather than fixed. The injector can be removed at controlled moments during the molding process, providing flexibility to break the molding bead at the optimal time. This dynamic capability ensures connection integrity while maintaining reasonable device complexity.
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 prevents the tearing of the molding bead during demolding, preserving the integrity of the bond between the transparent plate and the molded part, ensuring high-quality lens operation.
Implementation Method 1
at least one injection passage intended to allow an introduction of molding product into the impression, the injection passage being provided between the transparent plate and the molding element
Implementation Method 2
The molding product is then solidified, resulting in the formation of a molded part made of molding product in the cavity
Implementation Method 3
the assembly member urges the transparent plate towards a discontinuous peripheral support surface of the face of the molding element
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The molding device (100), for forming lenses by molding, comprises: a molding element (101) having cavities (102) formed in a face (103) of the molding element (101); a transparent plate (104) held relative to the molding element (101) so as to form, with the cavities (102), an impression (105) intended to allow the formation of a plurality of lenses; at least one injection passage (106) intended to allow the introduction of molding product into the impression (105), the injection passage (106) being provided between the transparent plate (104) and the molding element (101); a molding product injector (109) arranged so as to allow the introduction of molding product into the injection passage (106).The injector (109) is removable, and said molding device (100) is configured so as to permit removal of the injector (109) while maintaining the retention of the transparent plate (104) relative to the molding element (101).