Thermosetting Lens Manufacturing for Integrated Light Shielding
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Solution Overview
Problem
Existing light emitting devices face issues with light leakage and inefficient light reflection/absorption due to the use of metal films as light-reflecting members, which are prone to degradation and require complex manufacturing processes.
Innovation Solution
A lens structure comprising a cover part and a light-shielding part, where the cover part is formed of a thermosetting first resin with a flange part thicker than the connection part, and the light-shielding part is made of a thermosetting second resin with higher light-absorptance or reflectance, ensuring stable bonding and reduced light leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal film is used as the light-reflecting member formed by vacuum vapor deposition, then light reflection is achieved, but the manufacturing process becomes complex and the reliability deteriorates due to degradation
Solution Approach 1:
The patent replaces the metal film (which degrades over time) with a resin-based light-shielding part that is more durable and stable. The resin material, particularly the light-shielding resin with high light absorptance, provides long-term reliability without the degradation issues of metal films formed by vacuum vapor deposition.
Solution Approach 2:
The patent changes the material parameter from metal to resin, and specifically selects a resin with high light absorptance (greater than 90%) for the light-shielding part. This parameter change eliminates the need for complex vacuum vapor deposition while achieving stable light reflection/absorption functionality.
2Strength
If the flange part thickness is increased to improve bonding stability, then bonding strength is improved, but material consumption increases
Solution Approach 1:
The patent applies different material properties to different parts of the lens assembly. The cover part uses a standard resin, while the light-shielding part uses a specialized resin with high light absorptance. The flange part thickness is optimized locally to provide sufficient bonding strength (greater than the connection part thickness) without excessive material consumption throughout the entire assembly.
Solution Approach 2:
The patent uses composite material construction with two different resins: a cover resin for the transparent cover part and a light-shielding resin with high light absorptance for the light-shielding part. This composite approach allows optimal material selection for each functional requirement, achieving bonding strength where needed while minimizing overall material consumption.
3Object-generated harmful factors
If a light-shielding part is added to cover lateral surfaces, then light leakage is reduced, but device complexity increases
Solution Approach 1:
The patent merges the light-shielding function with the existing lens structure by making the light-shielding part an integrated component formed from the same mold as the cover part. The light-shielding part covers the lateral surfaces of the connection part, combining structural support and light shielding functions in a single integrated assembly, thereby reducing rather than increasing device complexity.
Solution Approach 2:
The light-shielding part is formed in advance during the molding process, before assembly. The high light absorptance resin is pre-formed to match the lateral surfaces of the connection part, eliminating the need for additional post-assembly light shielding measures and simplifying the overall manufacturing process.
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
The proposed lens structure effectively reduces light leakage and enhances light reflection/absorption, providing improved durability and manufacturing efficiency through a simplified process using thermosetting resins.
Implementation Method 1
injecting a thermosetting first resin in a first mold and curing the first resin, to form a cover blank
Implementation Method 2
injecting a thermosetting second resin having a greater light absorptance or a greater light reflectance than the thermosetting first resin into the second mold, and curing the thermosetting second resin
Implementation Method 3
the light-shielding part covers outer lateral surfaces of the one or more lateral side walls and is formed of a thermosetting second resin having a greater light-absorptance or a greater light-reflectance than the thermosetting first resin
Implementation Method 4
the light-shielding part covers outer lateral surfaces of the one or more lateral side walls and is formed of a thermosetting second resin having a greater light-absorptance or a greater light-reflectance than the thermosetting first resin
Data Source
AI summary
A method of manufacturing a lens includes: injecting a thermosetting first resin in a first mold, and curing the thermosetting first resin, to form a cover blank having cover parts; removing a part or all parts of the first mold; arranging the cover blank in a second mold; injecting a thermosetting second resin having a greater light absorptance or a greater light reflectance than the thermosetting first resin into the second mold and curing the thermosetting second resin, to form a lens blank having a light-shielding part between adjacent ones of the cover parts; taking out the lens blank from the second mold; cutting the lens blank at the light-shielding part located between the adjacent ones of the cover parts to obtain individual lenses having lateral side walls and flange parts extending outward from lower-end portions of the lateral side walls, which are both covered by the light-shielding part.