Overmolded Lens Assembly for Thick Lens Warping Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing larger lenses for applications such as radar and FDS devices is challenging due to warping and sinking issues, as well as the high cost of machining. Existing molding processes require longer cooling times, which can lead to material warping and suboptimal lens performance.
Innovation Solution
A two-step overmolding process is used to manufacture lenses, where a lens base and a lens fill are molded separately using plastics. This process reduces the time required to produce a lens and lowers manufacturing costs while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If larger and thicker lenses are manufactured using traditional molding processes, then more powerful and focused signal beams are achieved, but warping and sinking occur due to longer cooling times
Solution Approach 1:
The lens is divided into two separate components: a lens base and a lens fill. These are manufactured separately using injection molding and then bonded together. This segmentation allows each component to be molded with optimal thickness, avoiding warping while achieving the desired overall lens thickness for powerful signal beams.
Solution Approach 2:
The lens base and lens fill are bonded together to form a complete lens assembly. This merging combines the advantages of both components: the structural integrity of the lens base with the optical properties of the lens fill, achieving both manufacturing precision and optical performance.
2Manufacturing precision
If larger lenses are manufactured using machining processes, then warping is avoided, but manufacturing cost increases significantly
Solution Approach 1:
By segmenting the lens into two moldable components, the invention enables the use of injection molding for both parts. This eliminates the need for expensive machining operations while maintaining precision, as each component can be molded separately and then bonded together.
Solution Approach 2:
The invention changes the manufacturing parameters from traditional single-step molding or machining to a two-step injection molding process with bonding. This parameter change allows for cost-effective production of large lenses with precise dimensions, avoiding both warping and high machining costs.
3Productivity
If traditional single-step molding is used for large lenses, then manufacturing time is reduced, but warping occurs due to extended cooling requirements
Solution Approach 1:
The lens manufacturing is segmented into two separate injection molding operations. Each operation produces a component with optimal cooling time, preventing warping. The components are then quickly bonded together, maintaining high productivity while eliminating warping issues associated with single-step molding of thick lenses.
Solution Approach 2:
The lens base is molded and cooled completely before the lens fill is added. This preliminary action allows the first component to reach optimal dimensions without warping, and the second component is then molded and bonded to it, maintaining manufacturing efficiency while ensuring precision.
Data Source
AI summary
Some embodiments of the technology disclosed herein relate to a lens assembly including a lens base and a lens fill. The less base is constructed of a first material and defines a lens interior surface and a plurality of ribs extending axially from the lens interior surface. The plurality of ribs define a plurality of cavities between the plurality of ribs. The lens fill is constructed of a second material and is located within the plurality of cavities. The first material includes a plastic and the second material includes a plastic.