Square Lens Press-Molding with Corner Protrusions
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Solution Overview
Problem
Conventional methods for manufacturing square optical lenses face challenges in achieving high productivity, accurate assembly, and cost-effectiveness due to the need for precise quadrangular dies, which also lack protective features for the lens surface, making them prone to scratches and increasing handling complexity.
Innovation Solution
A method involving a mold assembly with a cavity die and a core die of different cross-sectional shapes, where the core die moves relative to the cavity die to form the lens surface, creating protrusions for protection and a wider bonding area, allowing for press-molding of optical elements with a non-press-molding zone to facilitate material flow and reduce assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If quadrangular cavity die and core die are used to press-mold square lens, then the lens can be directly mounted on mounting surface with automatic optical axis alignment, but the manufacturing cost increases due to high precision requirements for both dies and assembly complexity
Solution Approach 1:
The invention extracts the protective function from a separate component and integrates it into the lens structure itself by forming protrusions at the corners of the square lens. This eliminates the need for additional protective members while maintaining the scratch protection function.
Solution Approach 2:
The invention segments the die structure into a circular core die and a quadrangular cavity die with different cross-sectional shapes. This segmentation allows the core die to be simpler in form while the cavity die provides the mounting functionality, reducing overall manufacturing complexity.
2Ease of operation
If quadrangular cavity die and core die are used to press-mold square lens, then the lens can be directly mounted on mounting surface, but the manufacturing cost increases due to high precision requirements for dies
Solution Approach 1:
The invention uses a circular core die instead of a complex quadrangular core die. The circular shape is simpler and cheaper to manufacture with lower precision requirements, while the quadrangular mounting functionality is provided by the cavity die alone.
Solution Approach 2:
The invention employs asymmetric cross-sectional shapes for the cavity die (quadrangular) and core die (circular). This asymmetry allows each die to be optimized for its specific function, with the core die being simpler and cheaper to manufacture.
3Productivity
If square lens is manufactured without protective members, then the handling complexity increases due to risk of lens surface scratches
Solution Approach 1:
The invention merges the protective function with the structural form of the lens by forming protrusions at the corners. This combines the lens body and protective elements into a single integrated structure, eliminating the need for separate protective members.
Solution Approach 2:
The protective protrusions are formed during the press-molding process itself, before the lens enters service. This preliminary formation of protective features prevents scratches during handling without requiring additional protective measures during operation.
4Manufacturing precision
If conventional press-molding is used without non-press-molding zone, then the material flow is restricted and assembly complexity increases
Solution Approach 1:
The invention applies partial press-molding by creating a non-press-molding zone at the corners of the cavity die. This allows material to flow freely in these regions to form protective protrusions, while the central lens area receives full press-molding for shape accuracy.
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 enhances productivity by simplifying the assembly process, reducing costs, and providing a larger adhesive area for secure mounting while protecting the lens surface from scratches, thus improving the handling and stability of optical elements.
Implementation Method 1
heating the glass material so as to soften the same
Implementation Method 2
pressing the cope mold against the drag mold so as to cause the molding surfaces of the cope mold, the drag mold and the holder to press (clamping or die fastening) the glass material
Data Source
AI summary
A method of producing an optical element, in which a first and a second die are cooperated with each other so as to press-mold a material in order to produce an optical element including a lens portion, the first die has a circular cross-sectional shape, and the second die defines therein an interior space having a polygonal cross-sectional shape with respect to the direction of die-fastening, the first die is adapted to enter into the interior space of the second die in the direction of die-fastening in the interior space so to press-mold the material in order to form the lens surface while the material is bulged out through gaps between the first die and the second die around the lens surface whereby forming protrusions. An optical element and a mold assembly for an optical element are also provided.