Plastic Light-Folding Element Gate Vestige Structure
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Solution Overview
Problem
The quality requirements for plastic light-folding elements in portable electronic devices are increasing, necessitating a stable control of the plastic material filling during the injection process to avoid defects and improve surface accuracy.
Innovation Solution
A plastic light-folding element with an incident surface, an exit surface, at least one reflective surface, connecting surfaces, and a gate vestige structure, where the gate vestige structure has a high area ratio to control the filling speed of the plastic material and the arc step structure on optical surfaces enhances surface accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the plastic material filling speed is increased during injection, then productivity is improved, but manufacturing precision deteriorates due to defects and poor surface accuracy
Solution Approach 1:
The patent applies local quality by creating a gate vestige structure with specific area ratio (33%≤Ag/At≤90%) at the gate region of the connecting surface, and arc step structures at specific locations on optical surfaces. These localized structural modifications control plastic material filling behavior at critical regions without affecting the entire mold cavity, thereby enabling high filling speed while maintaining surface accuracy at optical surfaces.
2Manufacturing precision
If the gate vestige structure area is increased, then manufacturing precision is improved by controlling filling speed, but device complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the gate vestige structure area ratio (Ag/At) to fall within the specific range of 33% to 90%, and by defining specific geometric parameters for arc step structures (radius, depth, position). These parameter optimizations control plastic material filling speed and pressure distribution, improving manufacturing precision while maintaining relatively simple structural forms that do not significantly increase device complexity.
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 stabilizes the filling process of the plastic material, reduces defects, and improves the surface accuracy of optical surfaces, leading to higher image resolution and reduced manufacturing costs.
Implementation Method 1
The reflective surface is configured to fold the imaging light
Implementation Method 2
The incident surface is configured to lead an imaging light enter the plastic light-folding element
Implementation Method 3
The exit surface is configured to lead the imaging light exit the plastic light-folding element
Data Source
AI summary
A plastic light-folding element includes an incident surface, an exit surface, at least one reflective surface, at least one connecting surface and at least one gate vestige structure. The incident surface is configured to lead an imaging light enter the plastic light-folding element. The exit surface is configured to lead the imaging light exit the plastic light-folding element. The reflective surface is configured to fold the imaging light. The connecting surface is connected to the incident surface, the exit surface and the reflective surface. The gate vestige structure is disposed on the connecting surface. At least one of the incident surface, the exit surface and the reflective surface includes an optical portion and an arc step structure, the arc step structure is disposed on a periphery of the optical portion, and an arc is formed by the arc step structure centered on the optical portion.