Recessed Core Lens for Stress-Free Thick Optical Components
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Solution Overview
Problem
The challenge is to create a thick optical component with a smaller size without increasing molding time, while preventing the generation of vacuum bubbles and residual internal stress, which is difficult due to the difference in contraction between the surface plastic layer and the inner plastic portion during the injection molding process.
Innovation Solution
The solution involves integrating a core lens with a covering plastic, where the covering plastic is introduced into recessed portions on the front and back surfaces of the core lens, allowing for a smaller outer shape without increasing molding time and eliminating voids and internal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of optical component is increased, then the optical performance is improved, but vacuum bubbles and residual internal stress are generated due to contraction difference between surface and inner portions
Solution Approach 1:
The invention divides the optical component into two segments: a core lens and a covering plastic layer. The core lens is formed first with predetermined thickness, then the covering plastic is injected to cover the front and back optical surfaces. This segmentation allows the core lens to provide the necessary optical thickness while the covering plastic protects the surfaces, avoiding the contraction stress problems that would occur in a monolithic thick component.
2Volume of moving object
If the thickness of optical component is increased, then the optical performance is improved, but the molding cycle time is considerably lengthened
Solution Approach 1:
The core lens is formed in advance with the predetermined thickness required for optical performance. Then, in a separate injection molding step, the covering plastic is injected to cover the surfaces. This preliminary formation of the core lens allows the final assembly to be completed quickly without requiring extended cooling times for a single thick component, thus reducing the overall molding cycle time.
3Volume of moving object
If the outer shape of optical component is reduced to match core lens dimensions, then the component size is reduced, but it becomes difficult to prevent vacuum bubbles and internal stress
Solution Approach 1:
The covering plastic is injected to cover only the front and back optical surfaces of the core lens, creating a local quality enhancement at the critical optical interfaces. This localized covering protects the optical surfaces and reduces stress concentration at the interfaces, preventing vacuum bubbles and internal stress while maintaining a compact overall component size that matches the core lens dimensions.
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 enables the production of a thick optical component with a smaller size, maintaining optical performance and reducing the visibility of the bonded interface, thus achieving a compact design without the drawbacks of increased molding time or internal stress.
Implementation Method 1
a covering plastic is introduced onto the front and back optical surfaces of the core lens through a recessed portion
Implementation Method 2
an increase in stress occurs due to the difference between contraction of a surface plastic layer, which first solidifies during a molding process, and contraction of an inner plastic portion, which solidifies afterwards
Data Source
Figure 1A~2
Figure 3A~3B
Figure 4A~4K
AI summary
A recessed portion (4), through which a covering plastic (14) that has been melted and that is used for covering a core lens (1) is introduced in a bifurcating manner, is formed in the core lens (1), and the covering plastic (14) is introduced simultaneously onto the front and back surfaces (5, 6) of the core lens (1) through the recessed portion (4).