Resin Lens Mold Release via Temperature and Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing wafer level lens arrays made of resin struggle to smoothly release the lenses from molds without damaging them, leading to potential deformation and optical aberration, and are limited in applicability to specific lens shapes.
Innovation Solution
A molded product manufacturing apparatus and method that control pressure and temperature to gradually release the lenses, maintaining a specific temperature during curing and reducing pressure in stages as the mold cools, to prevent distortion and ensure high-quality lens production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an external force is applied to release the wafer level lens array from the mold, then the molded product can be released, but the lenses may be damaged, surfaces scratched, or spherical surfaces deformed
Solution Approach 1:
The patent applies parameter changes by controlling temperature and pressure conditions during mold release. Specifically, the mold temperature is maintained at or above the glass transition temperature of the resin while release pressure is applied, and then the mold is cooled. This parameter control allows the resin to be in a rubbery state during release, reducing adhesion and enabling easy release without damaging the lenses or their spherical surfaces.
Solution Approach 2:
The patent utilizes phase transitions of the resin material, specifically the glass transition, to facilitate mold release. By maintaining the mold temperature at or above the glass transition temperature during release, the resin transitions to a rubbery state with reduced adhesion to the mold. After release, the mold is cooled to complete the phase transition and solidify the lenses.
2Productivity
If conventional release methods are used, then mold release can be achieved, but lens deformation and optical aberration occur
Solution Approach 1:
The patent controls temperature and pressure parameters systematically: maintaining mold temperature at or above the glass transition temperature during release, applying controlled release pressure, then cooling the mold. This parameter control ensures high release efficiency while preserving optical properties by preventing lens deformation and maintaining spherical surface integrity.
Solution Approach 2:
The patent incorporates feedback by monitoring the mold temperature relative to the glass transition temperature of the resin. The release process is controlled based on this temperature feedback, ensuring that release occurs only when the resin is in the appropriate rubbery state, thereby guaranteeing both high release efficiency and preserved optical properties.
3Ease of operation
If the mold is cooled during or before release, then release may be facilitated, but lens quality deteriorates due to deformation
Solution Approach 1:
The patent inverts the conventional approach by maintaining high temperature (at or above glass transition temperature) during release instead of cooling. This inversion allows the resin to remain in a rubbery state with reduced adhesion, enabling easy release without deformation. Cooling is applied only after release is complete, ensuring lens shape accuracy is preserved.
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 allows for the smooth and efficient release of high-quality lenses with maintained optical properties, preventing deformation and improving productivity while being applicable to various lens shapes.
Implementation Method 1
a curing reaction of the heat-curable resin is progressing so that the heat-curable resin is molded
Implementation Method 2
during a process for decreasing the internal temperature of the mold
Data Source
AI summary
A molded product manufacturing method and a molded product manufacturing apparatus are realized, each of which has improved quality and productivity of a molded product. A pressure to be applied to an upper mold (ML) and a lower mold (ML) is reduced in stages during a process from a start of decrease in internal temperatures of the upper mold (ML) and the lower mold (ML) to a complete mold-release of a resin component (W). This prevents an excessive load from being applied to the resin component (W) which has been molded but has not been mold-released.