Micro Lens Array Molding Apparatus Alignment
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Solution Overview
Problem
Existing technologies face challenges in manufacturing optical components like micro lens arrays with different patterns on both surfaces, particularly for micro light emitting diode (LED) display modules.
Innovation Solution
A molding apparatus is designed with a lower base and an upper base, each equipped with a jig that accommodates a mold. The apparatus includes drivers for positioning and aligning the molds, heaters for curing thermosetting resin, and a vacuum device for fixing the molds. A controller coordinates the operation of these components to ensure precise alignment and curing of the molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a micro lens array with color conversion function is manufactured using existing molding methods, then the lens units and bank units can be formed, but it is difficult to manufacture optical components with different patterns on both surfaces with high precision alignment
Solution Approach 1:
The patent introduces an alignment camera as an intermediary device to detect and measure the relative position between upper and lower molds. The alignment camera captures images of alignment marks on both molds and calculates positional deviations, serving as a mediator that enables precise alignment measurement without direct mechanical contact between the molds
Solution Approach 2:
The patent replaces traditional mechanical alignment methods with an optical measurement system. Instead of using mechanical fixtures or direct physical contact for alignment, the system uses an alignment camera with image processing to detect alignment marks and determine relative positions, substituting mechanical alignment with optical-field-based measurement
2Manufacturing precision
If traditional molding apparatus is used for manufacturing optical components, then the manufacturing process is simple, but it cannot achieve precise alignment and positioning of molds with different patterns on both surfaces
Solution Approach 1:
The patent performs preliminary alignment measurement using the alignment camera before the actual molding process. The system detects the relative position of upper and lower molds in advance, calculates alignment deviations, and provides feedback for position correction, ensuring that precise alignment is achieved before resin injection and curing
Solution Approach 2:
The patent implements a feedback control mechanism where the alignment camera continuously monitors the relative position of molds, and the controller adjusts the positioning based on the detected alignment deviations. This closed-loop feedback system ensures that alignment precision is maintained throughout the molding process
3Manufacturing precision
If multiple separate processes are used for molding, alignment, and curing, then each process can be optimized independently, but the overall manufacturing time and complexity increase
Solution Approach 1:
The patent combines alignment measurement, positioning control, and molding operations into a single integrated apparatus. The alignment camera, positioning mechanisms, and molding components work together in coordination, allowing alignment and molding to be performed in a unified process flow rather than as separate sequential steps
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 molding apparatus effectively manufactures micro lens arrays and other optical components with complex patterns on both surfaces, enhancing the production efficiency and quality for micro-LED display modules.
Implementation Method 1
the lower jig may include a first heater configured to heat-cure thermosetting resin applied to the lower mold, and the upper jig may include a second heater configured to heat-cure thermosetting resin applied to the upper mold
Implementation Method 2
a vacuum device configured to generate a vacuum, the lower jig may include a first vacuum tube that is selectively connected to the vacuum device and fixes the lower mold by the vacuum generated by the vacuum device
Data Source
AI summary
The present disclosure relates to a molding apparatus for manufacturing an optical component, such as a micro lens array, for use in a micro-LED display module. A molding apparatus according to one embodiment of the present disclosure may comprise: a lower base having a lower jig on which a drag is seated; an upper base located on one side of the lower base and having an upper jig on which a cope is seated; a first driving unit that turns the upper base over and positions same above the lower base; an alignment camera unit that detects an alignment between the cope seated on the upper jig and the drag seated on the lower jig when the upper base is located above the lower base; a second driving unit provided under the lower base to move the lower base; and a control unit that aligns the drag and the cope by controlling the second driving unit according to the detection of the alignment camera unit.