Optical Lens Peripheral Thickness Design for Crack-Free Cutting
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Solution Overview
Problem
Current plastic lenses are prone to cracking during the cutting process due to their large thickness, leading to damage and loss, especially when being separated from the molding die in injection molding processes.
Innovation Solution
The optical lens design includes a peripheral portion with a thinner second surrounding portion that has a lens cutting surface extending along the optical axis, allowing the cutting position to be located at this thinner section, reducing the risk of internal cracking and optimizing the lens's dimensions for improved strength when installed in a lens barrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the lens is made with large thickness to ensure structural strength, then the lens can maintain its shape and strength, but the lens is prone to cracking during the cutting process
Solution Approach 1:
The lens is divided into two distinct regions with different thicknesses: a first surrounding portion with larger thickness for structural strength and a second surrounding portion with smaller thickness for crack-free cutting. This segmentation allows each region to fulfill its specific functional requirement without compromising the other.
Solution Approach 2:
Different regions of the lens are assigned different thickness qualities according to their functional needs. The first surrounding portion maintains larger thickness for overall structural support, while the second surrounding portion has reduced thickness specifically at the cutting position to enable reliable cutting without cracking.
2Ease of manufacture
If the lens is cut at the standard position to separate it from the molding die, then the lens can be removed for further processing, but the large thickness causes internal cracking and lens damage
Solution Approach 1:
The lens is pre-formed during injection molding with a thinner second surrounding portion that extends along the optical axis. This preliminary structural preparation ensures that when cutting occurs, the material is already optimized for clean separation without cracking, eliminating the need for post-cutting repairs or rejections.
3Manufacturing precision
If the lens maintains standard dimensions to ensure optical performance, then the optical quality is preserved, but the lens occupies excessive space in the lens barrel
Solution Approach 1:
The lens structure is optimized with local thickness variation: the first surrounding portion maintains sufficient thickness for optical integrity, while the second surrounding portion has reduced thickness that decreases the overall width and volume of the lens, allowing more efficient space utilization in the lens barrel without compromising optical performance.
Data Source
AI summary
An optical lens, including: an optical portion located at a central position; and a peripheral portion surrounding the optical portion. The peripheral portion includes: a first surrounding portion connected to the optical portion and surrounding the optical portion; and a second surrounding portion surrounding the first surrounding portion and having a lens cutting surface. A thickness of the first surrounding portion in a direction of an optical axis of the optical lens is greater than a thickness of the second surrounding portion in the direction of the optical axis of the optical lens, and the lens cutting surface extends from an object side of the second surrounding portion to an image side of the second surrounding portion along the direction of the optical axis. The optical lens disclosed in the present disclosure has an advantage of preventing internal cracking of the optical lens when the optical lens is cut.