Long-Length Lens Rib Design for Uniform Solidification
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Solution Overview
Problem
The existing manufacturing process for long-length lenses, such as fθ lenses, results in variations in cross-sectional area along the lens length, leading to differences in flowability and solidification time, which increases the likelihood of defects in the molded product.
Innovation Solution
Incorporating rib portions on either side of the lens portion, with varying cross-sectional areas that complement the lens portion's decreasing thickness from center to ends, reducing overall cross-sectional area variations and enhancing even solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the cross-sectional area of the lens portion decreases gradually from center toward each end in longitudinal direction, then the lens achieves proper optical focus, but the difference in flowability and solidification time between portions increases
Solution Approach 1:
The patent applies local quality by introducing rib portions with specific cross-sectional area variations at different locations along the longitudinal direction. The rib portions have larger cross-sectional areas at the ends and smaller areas toward the center, which locally compensates for the lens portion's thickness variation. This creates different structural characteristics in different regions: the lens portion maintains its optical function while the rib portions manage the flowability and solidification issues locally.
Solution Approach 2:
The rib portions act as intermediary structures between the lens portion and the mold cavity. These rib portions with varying cross-sectional areas serve as transition zones that mediate the flow of resin material, distributing the flow more evenly throughout the lens structure and reducing the flowability differences that would otherwise occur between the thinnest and thickest portions.
2Measurement precision
If the cross-sectional area varies greatly along the length of the lens, then the lens achieves proper optical characteristics, but the time difference for material solidification between thinnest and thickest portions increases
Solution Approach 1:
The rib portions are designed with non-uniform cross-sectional areas that vary along their longitudinal extent. Specifically, the rib portions have larger cross-sectional areas at their end portions and smaller areas toward their center portions. This local variation in the rib portions compensates for the corresponding variations in the lens portion, creating a more uniform overall solidification pattern and reducing the time difference between the thinnest and thickest portions.
3Measurement precision
If larger cross-sectional area is used in the lens portion, then the optical focus is improved, but the material usage and manufacturing cost increase
Solution Approach 1:
The patent optimizes material usage by applying local quality through strategically placed rib portions. Rather than uniformly increasing the cross-sectional area throughout the entire lens, the rib portions are positioned only where needed to compensate for the varying thickness of the lens portion. This localized approach maintains the necessary optical focus while minimizing excess material usage, as the rib portions only add material where required to balance the flowability and solidification characteristics.
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 configuration reduces the likelihood of defects, shortens the molding cycle, and decreases material usage, thereby increasing productivity and reducing manufacturing costs.
Implementation Method 1
at least one of which is a curved lens surface having a refractive power
Data Source
AI summary
A lens includes a lens portion having two opposite oblong surfaces at least one of which is a curved lens surface having a reflective power. A cross-sectional area of the lens portion varies from a center toward each end in a longitudinal direction of the lens portion. A rib portion is disposed at each of two opposite sides of the lens portion adjacent to longer sides of the oblong surfaces of the lens portion, and extends along the longitudinal direction of the lens portion. A cross-sectional area of the rib portion varies along the longitudinal direction in a manner that renders variations of a cross-sectional area of a portion including the lens portion and the rib portion along the longitudinal direction of the lens portion smaller.