Optical Lens Flange Swelling Prevention via Local Concave Design
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Solution Overview
Problem
In injection molding of optical lenses for smartphones and similar devices, the flange portion often becomes swollen due to uneven filling pressure, making it difficult to position the lens accurately, as it requires a planar surface for proper alignment.
Innovation Solution
The optical lens design incorporates a cut section on its side surface with concave portions on both surfaces, specifically in regions where the filling pressure is high, to prevent swelling and ensure a planar surface, while the injection molding mold features convex portions to match these concave areas, ensuring uniform pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is performed with resin injected from a gate, then the optical lens can be manufactured efficiently, but the filling pressure becomes uneven causing swelling near the gate
Solution Approach 1:
The patent applies local quality by providing concave portions specifically in the high filling pressure region near the gate, while other regions maintain their normal shape. This localized structural modification allows the flange portion to accommodate pressure-induced deformation in specific areas without affecting overall dimensional accuracy or causing surface swelling that would interfere with positioning.
Solution Approach 2:
The concave portions are pre-formed in the mold cavity before injection molding occurs. This preliminary action anticipates the swelling that will occur during molding due to high filling pressure, providing a pre-compensated structure that prevents surface irregularities and ensures accurate positioning after the lens is manufactured.
2Measurement precision
If the flange portion is used as a reference plane for positioning, then accurate alignment can be achieved, but the surface becomes swollen due to high filling pressure
Solution Approach 1:
The patent maintains the flange portion as a reference plane by providing concave portions only in specific high-pressure regions, while other areas of the flange portion maintain their planar surface. This selective local modification allows the flange to serve its positioning function while accommodating deformation in non-critical areas.
3Manufacturing precision
If convex portions are added to the injection molding mold, then pressure distribution can be equalized, but the device complexity increases
Solution Approach 1:
The patent applies local quality by providing convex portions only in the high filling pressure region near the gate, rather than modifying the entire mold structure. These localized convex portions serve as pressure equalization protrusions that redirect resin flow and reduce pressure concentration, improving dimensional accuracy without significantly increasing overall mold complexity.
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 design allows for easy positioning of the optical lens by preventing swelling at high-pressure areas, maintaining a planar surface and preventing sink marks and variations in the lens surface, thus enhancing the accuracy and reliability of the imaging module.
Implementation Method 1
resin is injected into a cavity of a mold (injection molding mold) having a predetermined shape, and the cavity is filled with the resin
Implementation Method 2
by cooling down the injection molding mold, the resin with which the cavity is filled is cooled down and solidified
Data Source
AI summary
An optical lens has an optical function portion having an optical function, and a flange portion formed around the optical function portion. The flange portion has a cut section, which is formed by cutting a gate portion, on a side surface thereof. In a case where the following are viewed from a direction of the optical axis of the optical lens, a concave portion is provided in at least a portion of a region in which the flange portion overlaps with a region obtained by straight lines connecting together an optical axis center of the optical lens and both ends of the cut section, and the concave portion is provided on both surfaces of the flange portion.