Optical Device Bi-Injection Molding Integrated Cutting Edges
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Solution Overview
Problem
Conventional bi-injection molding processes for optical devices require multiple cutting steps, increasing manufacturing time and tolerance levels due to sequential component formation and alignment challenges.
Innovation Solution
A method involving a single bi-injection molding process where a supporting frame and light-transmissible element are formed simultaneously with integrated cutting edges, eliminating the need for pre-cutting and alignment, and using a two-mold set system to create flush cutting edges during sprue segment removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bi-injection molding process is used with sequential cutting steps, then two coupling components can be formed from various materials, but manufacturing time increases and manufacturing efficiency decreases
Solution Approach 1:
The patent merges the formation of two separate coupling components into a single integrated optical device structure. The supporting frame and light-transmissible element are formed as one piece through simultaneous injection molding, eliminating the need for separate cutting steps for each component and significantly improving manufacturing efficiency
2Ease of manufacture
If cutting steps are performed consecutively for first and second components, then components can be formed with cutting edges at various sites, but tolerance level of the final product increases
Solution Approach 1:
By combining the formation of both components into a single simultaneous molding process, the patent ensures that cutting edges are formed at the same time under controlled conditions. This eliminates the cumulative tolerance errors that occur when cutting steps are performed consecutively on separate components at different times
3Manufacturing precision
If first component is precisely placed into second mold set, then coupling accuracy can be achieved, but extra manufacturing time is required for alignment
Solution Approach 1:
The patent performs preliminary action by forming the supporting frame and light-transmissible element in a predetermined integrated configuration through simultaneous injection molding. The gate positions and component geometries are pre-designed to ensure proper alignment and coupling, eliminating the need for time-consuming alignment operations after component formation
Data Source
AI summary
An optical device includes a supporting frame and a light-transmissive element. The supporting frame has a frame body defining a through hole, and an extending portion extending from a side of the frame body and having a first cutting edge. The light-transmissible element is disposed on the supporting frame and has a main body aligned with the through hole, and an extending portion extending from a side of the main body and aligned with the extending portion of the supporting frame. The extending portion of the light-transmissible element has a second cutting edge that is flush with the first cutting edge of the supporting frame.