Light Diffusing Lens Multi-Layer Molding with Pre-Heated Insert
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Solution Overview
Problem
Conventional injection molding methods, such as insert molding, struggle to produce high-quality light diffusing lenses with uniform optical properties due to non-uniform internal stress and low adhesion between resin layers, especially in thick lenses, which leads to defects like sinks and prolonged molding times.
Innovation Solution
A production apparatus and method involving a pair of molds, a mold clamping apparatus, a transport device, a heating device, and an injection apparatus to laminate at least two resin layers, where the semifinished product is heated to a molten state before injecting additional resin layers, ensuring uniform adhesion and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If insert molding method is used to shorten molding time, then productivity is improved, but adhesion between resin layers deteriorates and internal stress becomes non-uniform
Solution Approach 1:
The invention changes the temperature parameter of the insert from room temperature (conventional) to heated state (near resin melting point). This parameter change enables the molten resin to properly adhere to the insert surface, achieving both high productivity through multi-layer molding and high manufacturing precision through uniform adhesion and stress distribution.
Solution Approach 2:
The invention applies preliminary heating action to the insert before the injection molding process. By pre-heating the insert to a temperature near the melting point of the resin, the surface is prepared in advance to receive the molten resin, ensuring proper adhesion when the resin is injected, thus resolving the adhesion problem while maintaining productivity.
2Manufacturing precision
If single-layer molding is used to ensure homogeneous structure, then manufacturing precision is improved, but molding time increases
Solution Approach 1:
The invention uses composite material structure with multiple resin layers, each layer being homogeneous in itself. By controlling the adhesion interface between layers through temperature management, the composite structure achieves overall homogeneity and optical quality while enabling faster production through multi-layer concurrent molding.
Solution Approach 2:
The insert (semifinished product) is prepared in advance through preliminary molding, and its surface is pre-heated before final assembly. This preliminary action allows the final molding process to proceed faster while maintaining the homogeneous quality required for optical applications.
3Productivity
If multicolor molding is used to create laminate structure, then productivity is improved, but thermal history difference causes non-uniform internal stress
Solution Approach 1:
The invention changes the temperature parameter of the insert from room temperature to heated state, matching it with the thermal state of the incoming molten resin. This parameter alignment eliminates thermal history differences between layers, ensuring uniform internal stress distribution while maintaining the productivity benefits of multi-layer molding.
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 efficient production of high-quality light diffusing lenses with enhanced optical properties and uniform stress distribution, overcoming the limitations of conventional methods by allowing simultaneous molding of multiple layers with improved adhesion and reduced residual stress.
Implementation Method 1
a heating device, having a heating means capable of entering and exiting the space between the pair of molds in an open state, which heats the fixed mold-facing surface of the inserted semifinished molded product until the surface becomes a molten state
Implementation Method 2
an injection apparatus which, after clamping of the pair of molds, injects a molding material into the final molded product cavity so that the molding material covers the molten surface of the semifinished molded product
Data Source
AI summary
It is an object of the present invention to provide a light diffusing lens production apparatus which makes it possible to efficiently produce a high-quality light diffusing lens having enhanced optical properties.The light diffusing lens production apparatus includes: a pair of molds 15, consisting of a fixed mold 16 and a movable mold 18, which forms a final molded product cavity 22 that defines the shape of a light diffusing lens 14; a mold clamping apparatus 62 in which the pair of molds 15 is attached; a transport device 66, having a chuck means capable of entering and exiting the space between the pair of molds 15 in an open state, which inserts a semifinished molded product 12 for the light diffusing lens 14 into the final molded product cavity 22; a heating device 68, having a heating means capable of entering and exiting the space between the pair of molds 15 in an open state, which heats the fixed mold 16-facing surface of the inserted semifinished molded product until the surface becomes a molten state; and an injection apparatus 64 which, after clamping of the pair of molds 15, injects a molding material into the final molded product cavity 22 so that the molding material covers the molten surface of the semifinished molded product 12.