Vortex Lens Metal Mold Center Crushing Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing vortex lenses with specific topological charge numbers using metal molds results in crushed center portions, leading to inadequate formation of ring-shaped intensity distributions in light.
Innovation Solution
A light flux controlling member with a vortex surface featuring multiple phase control surfaces and step surfaces, where the upper sides of the step surfaces intersect at the center, and the shortest distances between the step surfaces and the central axis are 5 μm or smaller, formed using a metal mold with a vortex surface molding surface created through radial cutting to prevent machining marks and ensure accurate ring-shaped intensity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal mold with a vortex surface is manufactured using conventional cutting methods, then the metal mold can be produced, but the center portion of the vortex surface becomes crushed and machining marks are generated
Solution Approach 1:
The patent applies preliminary action by designing the metal mold with a specific vortex surface geometry where the upper sides of the step surfaces intersect at the center portion. This preliminary design ensures that during the molding process, the molten material properly fills the cavity without causing center crushing, thus preventing the accuracy problem before it occurs during actual lens manufacturing
Solution Approach 2:
The patent changes the geometric parameters of the vortex surface by specifying that the upper sides of the step surfaces intersect at the center portion and that the shortest distances between the step surfaces and the central axis are 5 μm or smaller. These parameter changes optimize the mold design to prevent machining marks and center crushing while maintaining manufacturing feasibility
2Productivity
If a vortex lens is manufactured with a crushed center portion, then manufacturing is simpler, but the ring-shaped intensity distribution of light cannot be appropriately formed
Solution Approach 1:
The patent specifies precise geometric parameters for the vortex surface, including the intersection of step surface upper sides at the center and shortest distances of 5 μm or smaller between step surfaces and the central axis. These parameter changes ensure proper light transformation while maintaining manufacturing efficiency
Solution Approach 2:
The patent utilizes the hydraulic pressure of molten material during injection molding to properly fill the vortex surface cavity. The designed geometry ensures that the molten material flows correctly to form the precise vortex structure without center crushing, achieving both high productivity and precision through the molding process itself
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 solution enables the appropriate formation of light with a ring-shaped intensity distribution, suitable for optical communications, by preventing center crushing and maintaining precise surface intersections and distances.
Implementation Method 1
A vortex lens (vortex phase plate) is an optical element (light flux control member) having a vortex surface including a vortex-shaped phase control surface... When light having a Gaussian distribution with high intensity in the central part (Gaussian beam) is passed through the vortex lens, it is converted into light having a ring-shaped intensity distribution (vortex beam)
Data Source
AI summary
A light flux controlling member of the present invention includes: a vortex surface including a plurality of phase control surfaces having a vortex shape around a central axis and radially divided with the central axis at a center, and a plurality of step surfaces each configured to connect end portions of adjacent two phase control surfaces of the plurality of phase control surfaces. Upper sides of the plurality of step surfaces intersect each other at a center portion of the vortex surface. In side view, a curve extending from the center portion toward an outer periphery part of the vortex surface has an inflection point at the center portion of the vortex surface.