Optical Component Molding with Low Clamping Force
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Solution Overview
Problem
Conventional optical component molding apparatuses require large molding machines with high clamping forces, leading to surface shifts, tilts, and deformation issues, which affect precision and increase costs due to energy consumption and space requirements.
Innovation Solution
A molding apparatus with a mold clamping force range of 2 KN to 150 KN, allowing for precise molding of optical components with an outer diameter of 12 mm or less and surface roughness of Ra 20 nm or less, using a smaller machine that reduces strain and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If large molding machines with high clamping force (300 KN to 500 KN) are used, then the molds can be brought into close contact with each other, but surface shift and tilt occur affecting optical precision
Solution Approach 1:
The patent changes the clamping force parameter from the conventional 300-500 KN range to a lower 50-150 KN range, demonstrating that high optical precision can be achieved without excessive clamping force when proper mold design and alignment mechanisms are employed
2Force
If large molding machines are used, then high clamping force is achieved, but device size and installation space increase
Solution Approach 1:
The patent changes the clamping force parameter from 300-500 KN to 50-150 KN, enabling the use of smaller molding machines with reduced installation space while maintaining sufficient clamping capability for high-precision optical component molding
3Force
If large molding machines with high clamping force are used, then molds are brought into close contact, but mold deformation occurs leading to molding failure
Solution Approach 1:
The patent reduces the clamping force parameter from 300-500 KN to 50-150 KN, preventing excessive stress on mold structures while maintaining adequate contact pressure for high-precision molding through optimized mold design
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
The solution enables efficient, high-precision molding of optical components with reduced molding time, resin usage, and installation space, while preventing surface shifts and tilts, thus lowering production costs.
Implementation Method 1
the fixed mold and the movable mold to be brought into contact with each other by a mold clamping force within a range of 2 KN to 150 KN
Implementation Method 2
providing a void between the molds into which a resin material is to be injected
Data Source
AI summary
A molding machine includes a fixed mold and a movable mold. The molding machine is a so called micro molding machine which provides less than 150 KN of the mold clamping force for clamping the fixed mold and the movable mold. A positional shift length between both molds is preset at ±20 gm or less. Further, cavities are inserted in base molds of both molds respectively. Furthermore, cores are inserted in the cavities. The position of each cavity is adjustable with respect to each associated base mold. The position of each core is also adjustable with respect to each associated cavity. Moreover, the molding machine can simultaneously mold a plurality of optical components.