Lens Molding Apparatus Ultrasonic Vibration Mold Release

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing lens molding techniques face challenges in accurately processing thin-wall lenses with complex shapes, as they tend to be damaged during mold release due to high adhesion forces, and conventional vibration methods can further damage these delicate lenses.

Innovation Solution

A resin molding apparatus and method that uses a first and second mold with opposing transfer surfaces, where the resin material is cured between them, and vibration is applied from the side surface of the first mold to create a gap before separation, reducing the load on the lens and allowing for easy and accurate mold release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional vibration methods are applied to release the mold, then the adhesion strength between lens and mold is decreased, but the thin-wall lens is damaged due to direct contact vibration

Engineering Contradiction:

Improvemold release successVSAvoidlens integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent introduces a gas (intermediary substance) between the vibration source and the lens to transmit vibration indirectly. The gas acts as a mediator that reduces direct mechanical contact and associated damage while still enabling effective vibration for mold release.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct mechanical contact vibration with gas-transmitted vibration. This substitution changes the transmission medium from solid-to-solid contact to gas-mediated vibration, reducing mechanical stress and damage to the thin-wall lens.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If high adhesion force is used between mold and lens, then the lens shape is accurately transferred, but the lens is damaged during peeling off

Engineering Contradiction:

Improvelens shape accuracyVSAvoidlens integrity

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent applies vibration to the mold before complete separation occurs. This preliminary action reduces adhesion strength in advance, creating favorable conditions for gentle separation and preventing lens damage during the peeling process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses periodic vibration applied to the mold to cyclically reduce adhesion between the lens and mold surface. This periodic action facilitates gradual separation while maintaining lens integrity throughout the release process.

Inventive Principle:

Principle #19Periodic action

3Reliability

If direct contact vibration is applied to the lens, then the adhesion strength is decreased, but the whole lens is vibrated causing damage

Engineering Contradiction:

Improvemold release successVSAvoidlens damage from vibration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses gas as an intermediary medium to transmit vibration to the mold rather than directly to the lens. This intermediary approach allows effective vibration for adhesion reduction while minimizing harmful direct vibration effects on the lens.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Instead of applying vibration directly to the lens, the patent applies vibration to the mold indirectly through gas. This inverted approach achieves the same adhesion-reduction effect while avoiding direct harmful vibration of the lens.

Inventive Principle:

Principle #13The other way round (Inversion)

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 enables the easy and accurate molding of complex-shaped lenses by reducing the load on the lens during mold release, minimizing damage and ensuring precise separation without deforming or cracking the lens.

Implementation Method 1

curing means for curing the resin material to form a resin molded product

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Implementation Method 2

first vibration applying means for applying vibration from a side surface of the first mold so as to form a gap at least at a part between the first transfer surface and the resin molded product

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS9643345B2Resin molding apparatus and resin molding method

Publication Date: 2017.05.09 SHARP KK

AI summary

A lens molding apparatus (100) of the present invention includes: a mold (1) having a transfer surface (1a) for transferring a predetermined lens shape to a resin material; a mold (2) having a transfer surface (2a) for transferring a predetermined lens shape to the resin material; a support device (3) for moving the mold (1); a heating device (4) curing the resin material so as to form a lens, the resin material having been supplied between the transfer surface (1a) and the transfer surface (2a); and an ultrasonic vibrator (5) applying vibration from a side surface of the mold (1 or 2) so as to form a gap at least at a part between the transfer surface (1a or 2a) and the lens.