Optical Holding Device Injection Molding Precision
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Solution Overview
Problem
Existing holding devices for optical components suffer from structural inaccuracies at the end sections due to manufacturing processes, leading to errors in light transmission between optical components.
Innovation Solution
A method involving an injection molding process with a specific tool setup to form a holding device, where the first optical element is oriented and fixed on a flat end face, and the light guide channel is formed using a stamp, ensuring high accuracy in parallelism between the end faces and optical axes, allowing efficient and loss-free light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding is used to manufacture holding devices, then production efficiency is maintained, but structural inaccuracies occur at the end sections affecting optical alignment
Solution Approach 1:
The patent applies preliminary action by pre-positioning the first optical element and stamp within the mold cavity before the injection molding process begins. The optical element is placed on a support surface with its optical axis aligned to a reference plane, and the stamp is positioned to define the light guide channel. This pre-arrangement ensures that when the holding device is formed around these elements, the end faces and optical axes achieve high parallelism without requiring complex post-processing or tooling adjustments.
Solution Approach 2:
The patent uses an intermediary approach by introducing a stamp as a mediating tool that defines the light guide channel geometry. The stamp is positioned within the mold cavity and works in conjunction with the support surface to establish precise spatial relationships. This intermediary element allows the molding process to achieve high precision without directly complexifying the mold structure itself, as the stamp can be easily positioned and removed after forming.
2Reliability
If optical components are attached to inaccurate end sections, then device assembly is simplified, but light transmission errors occur between optical components
Solution Approach 1:
The patent ensures reliability of light transmission by performing preliminary alignment of the optical element's optical axis with the reference plane formed by the support surface and stamp positioning. This pre-alignment is locked in during the injection molding process, so that when the holding device is completed, the optical components are already positioned with high accuracy. This eliminates the need for subsequent realignment and ensures reliable light transmission between optical components mounted on the end sections.
3Manufacturing precision
If high precision parallelism is achieved between end faces, then optical axis alignment is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent achieves high precision parallelism while maintaining ease of manufacture by performing preliminary setup of the optical element and stamp within the mold cavity using simple positioning features. The support surface provides a reference plane, and the stamp is positioned relative to this plane using straightforward geometric relationships. This preliminary arrangement allows the injection molding process itself to produce the parallelism without requiring complex mold mechanisms or multi-step manufacturing processes.
Solution Approach 2:
The stamp serves as an intermediary that simplifies the manufacturing process while achieving high precision. Rather than requiring complex mold features to directly create the parallel end faces, the stamp is positioned as a mediating element that defines the light guide channel geometry and indirectly establishes the parallelism of the end faces. This intermediary approach maintains ease of manufacture by using a simple, removable stamp rather than complex integrated mold features.
Data Source
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Figure 3
AI summary
A method for producing a holding device (1), wherein a light guide channel (2) is formed in the holding device (1), which light guide channel (2) extends from a first end section (2a) to a second end section (2b) of the holding device (1), wherein the first end section (2a) has a receiving region in which a first optical element (3) is fastenable in form-fitting fashion, wherein the second end section (2b) has a stop surface (5) for connection to a second optical element (4), wherein the method comprises the following steps: a) providing the first optical element (3), b) providing an injection molding device for carrying out an injection molding process, wherein the injection molding device has two mold halves, c) introducing the first optical element (3) into the first mold half of the injection molding device, d) closing the mold halves, e) forming the first end section (2a) of the holding device, f) forming a shell, which surrounds the light guide channel (2), of the holding device (1), g) forming the second end section (2b), which terminates the shell of the holding device (1), together with the stop surface (5).