Integrally Molded Flash Lamp Lens and Holder
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Solution Overview
Problem
The miniaturization of portable electronic devices with imaging functions is limited by the separate assembly of flash lamp lenses and holders, which results in insufficient connecting strength and visible welding traces, making existing manufacturing methods time-consuming and costly.
Innovation Solution
A method involving injection molding to integrally form the flash lamp lens and holder as a single unit, using two different molding materials and processes to ensure a strong, seamless integration without visible welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhering/gluing technology is used to mount the flash lamp lens to the holder, then the assembly process is simple, but the connecting strength is insufficient and the lens module easily becomes separated
Solution Approach 1:
The patent combines the flash lamp lens and holder into a single integrated component manufactured through injection molding. This merging eliminates the need for separate assembly operations (such as gluing) while creating a unified structure with inherent strength, thereby simultaneously improving ease of manufacture and connecting strength.
2Strength
If welding technology is used to fix the flash lamp lens together with the holder, then the connecting strength is improved, but the welding trace is visible and the process is time-consuming and expensive
Solution Approach 1:
The patent integrates the lens and holder into a single molded part, eliminating the need for welding operations entirely. This approach removes the associated problems of visible welding traces and complex, time-consuming welding processes while maintaining strong structural integrity through the integrated design.
Solution Approach 2:
The patent replaces the mechanical welding process with an injection molding process that creates an integrated structure. This substitution eliminates the need for post-assembly welding operations, avoiding visible traces and reducing manufacturing complexity and time.
3Reliability
If the flash lamp lens is positioned apart from the camera lens to facilitate better imaging, then the imaging function is improved, but the portable electronic device cannot be miniaturized
Solution Approach 1:
The patent integrates the flash lamp lens and holder into a single component that can be positioned closer to the camera lens assembly. This integration allows for more compact spatial arrangement while maintaining the necessary imaging functionality, thereby enabling device miniaturization without compromising imaging performance.
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 simplifies the manufacturing process, enhances connecting strength, and eliminates the need for separate assembly, thereby reducing costs and enabling more compact device designs.
Implementation Method 1
The first step is to mold the lens by means of injecting a first molding material into a provided mold assembly. The second step is to mold the holder integrally with the molded lens by means of injecting a second molding material into the mold assembly.
Data Source
AI summary
A method for manufacturing a lens module (100) is provided. The lens module includes a flash lamp lens (20) and a holder (10) integrally formed/molded with the lens. The method includes at least three steps. The first step S1 is to mold the lens by means of injecting a first molding material into a provided mold assembly. The second step S2 is to mold the holder integrally with the molded lens by means of injecting a second molding material into the mold assembly to thereby yield the lens module. The third step S3 is to extract the lens module from the mold assembly.