Optical Receptacle Structure for Thin-Wall Weld Line Control
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Solution Overview
Problem
Existing optical receptacles with thin-wall portions experience molding defects and weld line formation during injection molding, which affect their performance when reduced in thickness.
Innovation Solution
An optical receptacle design with specific structural components, including a first part, a second part, side connection portions, a rib, and a thin-wall portion, is integrated to suppress molding defects and ensure weld lines do not interfere with the optical function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of optical receptacle is reduced to meet miniaturization demands, then the compactness is improved, but molding defects and weld lines are more easily formed in thin-wall portions
Solution Approach 1:
The patent applies local quality by strategically varying the thickness of different portions of the optical receptacle. The thin-wall portion is designed with a specific thickness range (0.3-0.8mm) that is thinner than other portions to reduce overall size, while critical areas maintain sufficient thickness to prevent molding defects. This localized thickness optimization allows the receptacle to achieve compactness without sacrificing manufacturing quality in critical regions.
Solution Approach 2:
The patent changes the thickness parameter of the thin-wall portion to a specific range (0.3-0.8mm) that balances miniaturization requirements with molding quality. By optimizing this parameter, the design achieves reduced overall thickness while preventing weld lines and molding defects in the thin-wall portion, resolving the contradiction between compactness and manufacturing precision.
2Reliability
If multiple recess portions are provided in optical receptacle to control light path, then the optical function is improved, but thin-wall portions are formed between recess portions causing molding defects
Solution Approach 1:
The patent applies local quality by designing the thin-wall portions between recess portions with optimized thickness (0.3-0.8mm), which is thinner than other wall portions but sufficient to prevent molding defects. This localized thickness control allows the formation of multiple recess portions for light path control while maintaining manufacturability and preventing weld lines in the thin-wall regions.
Solution Approach 2:
The patent incorporates gate marks or gate remnants in advance in specific locations of the optical receptacle. This preliminary action serves as a visual indicator and structural guide for the injection molding process, ensuring that material flow is properly controlled and weld lines are prevented in critical thin-wall portions, thereby facilitating the molding process despite the complex recess structure.
3Volume of moving object
If thin-wall portion is made thinner to reduce overall thickness, then the compactness is improved, but weld lines are easily formed in positions affecting optical performance
Solution Approach 1:
The patent applies local quality by differentiating the thickness of the thin-wall portion (0.3-0.8mm) from other wall portions, creating a graduated thickness structure. The thin-wall portion is thinned to reduce overall size, but critical areas near optical paths maintain sufficient thickness to prevent weld lines, thus achieving compactness without compromising optical performance.
Solution Approach 2:
The patent pre-positions gate marks or gate remnants in the molding design to control material flow patterns. This preliminary action ensures that even in thin-wall portions, the injection molding process directs material flow away from critical optical areas, preventing weld line formation in positions that would affect optical performance while still achieving overall thickness reduction.
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 design effectively suppresses molding defects and ensures that weld lines do not impair the optical function, maintaining performance even when the receptacle is thin.
Implementation Method 1
light emitted from photoelectric conversion element 10 disposed on substrate 10a enters optical receptacle 30 through first optical surface 31, is reflected by reflecting surface 32, and is emitted from optical receptacle 30 through second optical surface 33
Data Source
AI summary
An optical receptacle of the present invention includes a first part disposed on one side in a first direction, a second part disposed on the other side in the first direction, a pair of side connection portions that connect the first part with the second part, a rib that is disposed between the pair of side connection portions and connects the first part with the second part, and a thin-wall portion that is disposed in a space surrounded by the first part, the second part, and the pair of side connection portions. In the optical receptacle, a first weld line is designed to be formed on the thin-wall portion.