Single Mold Base for Sequential LED Lens Formation
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Solution Overview
Problem
Current multi-layer injection molding processes for LED lenses are costly and inefficient, requiring expensive equipment, multiple mold halves, and additional features for alignment, which increases tooling costs and material consumption.
Innovation Solution
A single mold base with a movable part that supports multiple shape-forming configuration sets, allowing for sequential formation of lens regions with each injection-molding shot, where each subsequent shot over-molds the previous region before full cooling, reducing the need for internal degating and minimizing equipment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-layer injection molding processes are used to manufacture LED lenses with large thickness differences, then the desired light distribution can be achieved, but the manufacturing cost and equipment complexity increase significantly
Solution Approach 1:
The lens manufacturing process is segmented into multiple injection shots that form different regions of the lens sequentially. Each shot creates a specific portion of the lens with controlled thickness, allowing precise thickness control without requiring complex multi-layer molding equipment. The lens is built up region by region through controlled material deposition and solidification.
Solution Approach 2:
The method performs preliminary actions by forming earlier regions of the lens before complete cooling occurs. Subsequent injection shots are introduced while previous regions are still in a semi-solid state, allowing them to be over-molded and integrated seamlessly. This eliminates the need for complete cooling cycles between shots and reduces equipment complexity.
2Shape
If multiple mold halves and core halves are used to build up molded components in layers, then complex lens shapes can be formed, but the capital cost of equipment increases
Solution Approach 1:
The mold structure employs dynamic elements including a rotatable platen that can rotate to position different mold cavities in sequence. The core assembly includes movable components that can shift positions during the injection process. This dynamic mold structure allows a single mold base to perform the function of multiple static mold halves, reducing capital equipment costs while maintaining the ability to form complex lens geometries.
Solution Approach 2:
A single mold base is designed to perform multiple functions by supporting multiple cavities and regions within it. The same mold cavity can form different lens regions at different times through the rotation and repositioning mechanisms. This multi-functional mold design eliminates the need for separate dedicated mold halves for each lens region, reducing overall equipment complexity and capital cost.
3Manufacturing precision
If parts are demolded and cooled before being replaced into cavity for subsequent shot, then proper alignment can be achieved, but production time and floor space requirements increase
Solution Approach 1:
The method introduces subsequent injection shots before the previously formed regions are fully cooled and solidified. The semi-solid state of earlier regions allows them to be over-molded and integrated with new material without requiring complete cooling cycles. This preliminary action approach maintains alignment precision through the mold structure itself rather than through cooling and repositioning operations.
Solution Approach 2:
The injection molding process operates continuously without interruption for cooling and repositioning between shots. The mold structure maintains all regions in position throughout the process, and material is injected continuously into the mold cavities. This continuous operation eliminates idle cooling time and keeps the production line actively forming lens regions throughout the cycle, significantly improving productivity.
4Manufacturing precision
If additional features are added to plastic components for location indexing and alignment, then proper positioning in mold is achieved, but tooling costs and material consumption increase
Solution Approach 1:
The alignment and positioning features are merged directly into the mold cavity structure itself rather than being added as separate features on the plastic component. The mold cavities are designed with built-in registration mechanisms and positioning elements that guide the thermoplastic material into the correct position during injection. This eliminates the need for additional alignment features on the lens components, reducing both tooling costs and material consumption.
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 efficient and cost-effective production of thick-walled LED lenses by minimizing equipment costs and optimizing floor space usage, while ensuring seamless light transmission through the lenses.
Implementation Method 1
Each cavity is shaped for forming one of first-formed, intermediate-formed and last-formed regions of the article in the cavities by a corresponding one of injection-molding shots
Implementation Method 2
The movable part is rotatable about an axis defined by the single mold base. The cavities may be supported and rotated by the movable part for their advancement to form subsequent article regions in each cavity
Implementation Method 3
This invention relates to an improved apparatus and method for forming thick-walled lenses from a suitable thermoplastic material
Data Source
AI summary
An injection-molding apparatus for article formation. The injection-molding apparatus includes a single mold base supporting at least one grouping of a plurality of shape-forming configuration sets. Each set is shaped for forming one layer of a multilayered article comprising an asymmetric surface. Each set may include at least one cavity which retains each article region formed by the preceding injection-molding shot(s). The single mold base includes an internal movable part which moves within the single mold base with respect to a stationary part such that relative positions of the shape-forming configurations are advanced for each set to form a subsequent article region in the cavities. Each subsequent shot may be prior to full cooling of the article region formed in the previous shot.