Optical Component Manufacturing with Amorphous Alloy Protective Shield
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Solution Overview
Problem
The existing methods for manufacturing optical components using metal materials can result in residual stress and deformation of optical elements due to rapid cooling, which affects their optical characteristics and durability.
Innovation Solution
A method involving a metal die with incident and emission side protective components that allow heat to escape, reducing temperature increase and stress in optical elements during injection molding with amorphous alloy, and a design with a narrower inner circumference to minimize heat transfer and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the optical element is injection molded integrally with the optical element holding component using molten metal material, then productivity is improved and dimensional accuracy is enhanced, but residual stress is generated and deformation occurs in the optical element
Solution Approach 1:
A protective component is introduced as an intermediary element between the molten metal material and the optical element. This protective component absorbs thermal energy from the molten metal, preventing direct heat transfer to the optical element, thereby eliminating residual stress and deformation while maintaining the integral molding process
Solution Approach 2:
The thermal parameters of the molding process are modified by introducing the protective component that changes the heat transfer characteristics. The protective component acts as a thermal barrier, altering the temperature distribution and cooling rate parameters to prevent thermal stress in the optical element
2Speed
If the cooling speed of the metal material is increased to improve productivity, then the manufacturing time is reduced, but the stress relaxation of the optical element becomes insufficient and residual stress is generated
Solution Approach 1:
The protective component serves as a thermal mediator that decouples the cooling speed of the metal material from the thermal experience of the optical element. It allows rapid cooling of the metal while protecting the optical element from thermal shock, enabling stress relaxation without generating residual stress
3Ease of manufacture
If the temperature of the optical element is raised during injection molding, then the metal material flows smoothly, but the optical characteristics of the optical element are changed or the optical element breaks
Solution Approach 1:
The protective component acts as a thermal shield that allows the metal material to be maintained at high temperature for smooth flow while preventing this heat from transferring to the optical element. This intermediary barrier preserves the optical characteristics by isolating the optical element from thermal exposure
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 method effectively suppresses residual stress and deformation, maintaining the optical characteristics and preventing breakage of optical elements while improving the productivity and dimensional accuracy of the optical component.
Implementation Method 1
because they allow heat from the optical element to pass through themselves and escape to the outside of the metal die
Implementation Method 2
the metal material is cooled by the metal die so as to form an optical element holding component formed from an amorphous alloy
Data Source
AI summary
A method of manufacturing an optical component that is provided with an optical element, and an optical element holding component that holds an outer circumferential portion of the optical element includes: placing the optical element on an interior side of a metal die that molds the optical element holding component, and in which an incident side protective component that protects an optical surface on an incident side of the optical element is placed against this optical surface on the incident side, and placing an emission side protective component that protects an optical surface on an emission side of the optical element against this optical surface on the emission side; and filling the interior of the metal die with a molten metal material so that the optical element holding component which is formed from an amorphous alloy is injection molded integrally with the optical element.