Injection Molding of Micro-Structured Optical Components
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Solution Overview
Problem
Current methods for manufacturing optical components with micro-structures are limited by high costs and difficulty in producing large-area components, especially when forming reflective films that require specific temperature control to avoid melting and deformation of the material.
Innovation Solution
A method using an injection molding device with a stationary and movable mold, pressure and temperature sensors, and a piezoelectric actuator to fill liquid crystal polymer into a mold cavity within a controlled crystallization temperature interval, allowing for the formation of micro-structured optical components with reflective films through chemical or physical vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep reactive ion etching (DRIE) or wet etching methods are used to manufacture optical components with micro-structures, then manufacturing precision of micro-structures is improved, but production cost increases and large-area components cannot be produced
Solution Approach 1:
The patent changes the manufacturing method from etching processes to injection molding, altering the fundamental parameters of the manufacturing approach. This enables mass production of large-area optical components with micro-structures while maintaining precision, as injection molding can produce large components cost-effectively and scale to large areas
Solution Approach 2:
The patent replaces the mechanical etching processes (DRIE, wet etching) with an injection molding process that uses a mold to directly form micro-structures. This substitution eliminates the need for complex etching equipment and multi-step processes, reducing cost and enabling large-area production
2Reliability
If high working temperature is used during reflective film coating, then film formation is improved, but liquid crystal polymer melts and deforms
Solution Approach 1:
The patent applies preliminary action by forming the micro-structures and completing the injection molding process before the reflective film coating step. This ensures the liquid crystal polymer component is already solidified and stable before exposure to high temperatures during film coating, preventing melting and deformation
Solution Approach 2:
The patent segments the manufacturing process into distinct stages: injection molding with controlled cooling to form solidified micro-structures, followed by reflective film coating. This separation allows each process to be optimized independently, with the molding stage ensuring structural stability before the high-temperature coating stage
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
Enables the efficient and cost-effective production of large-area optical components with precise micro-structures and reflective films, maintaining material stability during the reflective film coating process.
Implementation Method 1
a piezoelectric actuator
Implementation Method 2
detecting the crystallization temperature and the crystallization temperature interval including the crystallization temperature
Implementation Method 3
forming a reflective film on a micro-structure surface of the optical component having a micro-structure
Implementation Method 4
forming a reflective film on a micro-structure surface of the optical component having a micro-structure
Data Source
AI summary
A method of manufacturing an optical component having micro-structures is described. The method detects a crystallization temperature within a crystallization temperature interval for fully filling the molding material into a mold cavity to rapidly produce the optical element having a micro-structure with a large area.