Precision Lens Production via Temperature Gradient Inversion
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Solution Overview
Problem
Current methods for producing technical glass parts with high contour accuracy and surface quality, such as precision lenses, are costly and inefficient.
Innovation Solution
A method involving an injection molding process where a blank is cooled and then heated to invert its temperature gradient, allowing for subsequent blank molding into a technical glass part with high accuracy and surface quality, using glass types like B270, F2, or borosilicate glass, without direct contact to the optically effective surface during cooling and heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce precision lenses with high contour accuracy and surface quality, then the optical performance is improved, but the production cost increases and productivity decreases
Solution Approach 1:
The invention changes the temperature parameter profile by inverting the temperature gradient (cooling the outer regions first, then heating them) to optimize the molding process. This parameter change allows achieving high contour accuracy with reduced production costs by eliminating post-treatment steps
Solution Approach 2:
The invention performs preliminary cooling of the blank's outer regions before molding, creating a temperature gradient inversion that prepares the glass for optimal molding conditions. This preliminary action reduces the need for subsequent post-treatment, thereby reducing production costs while maintaining high precision
2Ease of manufacture
If conventional cooling and heating methods are applied to glass blanks, then the glass is prepared for molding, but the contour accuracy and surface quality deteriorate
Solution Approach 1:
The invention inverts the temperature gradient by cooling outer regions first and then heating them, changing the thermal parameters to optimize both molding preparation and surface quality. This parameter change ensures the glass is properly prepared for molding while maintaining high surface quality and contour accuracy
3Manufacturing precision
If post-treatment processes are applied to achieve desired contours, then the contour accuracy is improved, but the production time and cost increase
Solution Approach 1:
The invention performs preliminary cooling and heating actions during the molding process itself, creating the optimal temperature gradient inversion that allows the glass to be molded directly to the desired contour without requiring subsequent post-treatment processes. This eliminates additional time-consuming steps while maintaining high precision
Solution Approach 2:
The invention merges the cooling, heating, and molding operations into a single integrated process sequence. By combining these steps with the temperature gradient inversion approach, the process achieves desired contour accuracy directly during molding, eliminating the need for separate post-treatment operations and reducing production time
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
This approach reduces production costs while achieving precision lenses with contour deviations of less than 2 μm and surface roughness of 5 nm or less, eliminating the need for post-treatment to achieve desired contours.
Implementation Method 1
the blank is cooled and subsequently heated, inverting the temperature gradient of the blank
Data Source
AI summary
Disclosed is a method for producing a technical glass part, particularly meeting high requirements with respect to contour accuracy and surface quality, particularly a precision lens, wherein a blank including a cast-on section is produced using an injection molding process, wherein the blank is cooled down and subsequently heated, and wherein the blank subsequently is blank molded, particularly on both sides, into a technical glass part meeting high requirements with respect to contour accuracy and surface quality, particularly a precision lens.