Multicolor Molding Die with Hollow Shape for Optical Surface Protection
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Solution Overview
Problem
Existing multicolor molding techniques face challenges in precisely integrating optical elements with adjacent members without deforming the optical functional surfaces and in preventing air entrapment, which can lead to recessed portions and reduced precision in the molded pieces.
Innovation Solution
A molding die system comprising a first die for primary molding of an optical element with an optical functional surface and a second die for secondary molding of an adjacent member, where the second die has a hollow shape and air vents to prevent contact with the optical functional surface and efficiently discharge air, ensuring precise integration and preventing air entrapment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional secondary molding die directly contacts the optical element during secondary molding, then the molding process is simple, but the optical functional surface deforms and precision is reduced
Solution Approach 1:
The secondary molding die is divided into two distinct parts: a hollow shape portion that receives the optical element and an abutting portion that contacts only the non-optical surface. This segmentation allows the die to perform multiple functions without compromising the optical functional surface, resolving the contradiction between maintaining precision and managing structural complexity.
Solution Approach 2:
Different regions of the secondary molding die have different functional properties: the hollow shape portion is designed to accommodate and protect the optical functional surface, while the abutting portion is designed to contact and support the optical element at non-critical areas. This local differentiation enables precise molding without deforming the optical surface.
2Manufacturing precision
If air vents are not provided in the secondary molding die, then the die structure is simple, but air entrapment occurs causing recessed portions and reduced quality
Solution Approach 1:
Air vents are extracted as separate functional elements from the main body of the secondary molding die. These vents are specifically positioned to allow air escape during injection molding while maintaining the structural integrity and functional performance of the die, thus improving molded piece quality without excessive structural complexity.
3Productivity
If the movable die is used for both primary and secondary molding without modification, then the process is efficient, but air entrapment and deformation occur
Solution Approach 1:
The secondary molding die is prepared in advance with the hollow shape portion and abutting portion configured to receive and properly position the optical element before secondary molding begins. This preliminary configuration ensures that when the optical element is transferred from primary to secondary molding, it is correctly positioned and protected, preventing deformation and air entrapment while maintaining process efficiency.
Data Source
AI summary
In a molding die for multicolored molding, a second fixed die includes a hollow shape portion which is arranged at a portion associated with an optical functional surface. The second fixed die further includes an abutting portion which abuts on the optical element excluding the optical functional surface.