Optical Element Mold With Clearance-Based Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mold technologies for optical elements fail to effectively minimize outer-diameter deflection of optical elements during molding, requiring additional centering processes and leading to inaccuracies in coaxial alignment of upper and lower molds.
Innovation Solution
A mold configuration comprising an upper mold, a lower mold, a side-surface mold, and a sleeve, where the relationship between clearances between the neck parts and the hole is determined based on the distances between the centers of curvature of the optical surfaces and the outer-diameter height line, allowing precise formation of optical elements with reduced outer-diameter deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sleeve with linear inner circumference is used to hold molds and side-surface mold, then the molds can be positioned, but clearances between the side-surface mold and neck parts cause outer-diameter deflection and require additional centering processes
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-setting the clearances between the side-surface mold and neck parts based on the distances from centers of curvature to the outer-diameter height line. This preliminary determination of clearance relationships eliminates the need for post-molding centering processes and directly achieves accurate coaxial alignment during the molding process itself.
2Ease of operation
If clearances are provided between the side-surface mold and neck parts, then the molds can be assembled, but outer-diameter deflection occurs requiring additional centering processes
Solution Approach 1:
The patent determines the clearance relationships between the side-surface mold and neck parts in advance based on geometric parameters (distances from centers of curvature to outer-diameter height line). This preliminary action ensures that the molds are pre-aligned correctly, eliminating the need for time-consuming post-molding centering processes and directly reducing manufacturing cycle time.
3Device complexity
If the clearance relationship between hole and neck parts is not optimized, then assembly is simple, but outer-diameter deflection increases and mold life decreases due to interference
Solution Approach 1:
The patent applies parameter changes by optimizing the clearance parameters between the hole and neck parts based on specific geometric parameters (distances from centers of curvature to outer-diameter height line). By adjusting these clearance parameters to precise values, the patent prevents interference between components while maintaining assembly simplicity, thereby extending mold life and improving reliability.
4Productivity
If traditional molding methods are used, then the process is simple, but additional post-molding centering processes are required
Solution Approach 1:
The patent changes the clearance parameters of the mold configuration based on geometric relationships (distances from centers of curvature to outer-diameter height line). This parameter optimization enables the mold to self-align during molding, eliminating the need for separate centering processes and directly improving productivity despite the slightly more complex initial mold design.
Data Source
AI summary
A mold for an optical element includes: an upper mold including a first neck part; an upper-surface forming surface that is provided in a distal end of the first neck part of the upper mold, the upper-surface forming surface being configured to form an upper surface of the optical element; a lower mold including a second neck part; a lower-surface forming surface that is provided in a distal end of the second neck part of the lower mold, the lower-surface forming surface being configured to form a lower surface of the optical element; a side-surface mold having a hole into which the first neck part of the upper mold and the second neck part of the lower mold are inserted, a part of an inner surface of the hole being configured to form a side surface of the optical element; and a sleeve to accommodate these molds.