Mold Chase Alignment for Optical Component Fabrication
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Solution Overview
Problem
Conventional mold chases with flat inner surfaces fail to achieve the required alignment accuracy for integrating optical components, which is essential for precise optical signal coupling.
Innovation Solution
A molding apparatus with a mold chase featuring a lower portion with protrusions and an upper portion with recesses, allowing for precise alignment and integration of optical components through a two-step alignment process and imprinting with a moldable material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mold chases with flat inner surfaces are used, then the manufacturing process is simple, but the alignment accuracy for optical components is insufficient
Solution Approach 1:
The mold chase is pre-formed with protrusions and recesses that correspond to the optical components before the molding process. This preliminary structuring of the mold chase eliminates the need for complex post-molding alignment procedures, as the components are automatically positioned during the molding process itself.
Solution Approach 2:
The protrusions and recesses in the mold chase act as intermediary positioning features that mediate between the optical components and the mold chase structure. These features provide mechanical guidance and alignment during the molding process, ensuring precise positioning without requiring additional alignment mechanisms.
2Manufacturing precision
If additional alignment processes are added to improve optical component positioning, then alignment accuracy improves, but the manufacturing process complexity increases
Solution Approach 1:
The alignment function is merged with the molding process itself. The protrusions and recesses in the mold chase simultaneously provide structural support and precise positioning during the single molding operation, eliminating the need for separate alignment steps that would otherwise be required.
Solution Approach 2:
The mold chase structure performs self-alignment during the molding process. The protrusions and recesses automatically guide the optical components into their correct positions without requiring external alignment machinery or manual adjustment, making the system self-sufficient for positioning.
Data Source
AI summary
A molding apparatus includes a mold chase and a sensor. The mold chase includes an upper portion and a lower portion engaged with the upper portion to form a cavity therebetween for receiving a workpiece. The upper portion includes a top surface and an alignment mark on the top surface. A pattern is provided on at least one of inner surfaces of the upper and lower portions. The sensor facing the mold chase is configured to detect the alignment mark of the upper portion and a position of the workpiece in the mold chase.