Thick Wall Transparent Lens Light Guide Strip

Thick Wall Transparent Lens Light Guide Strip

thick-wall optical injection molding and micro-optical molding solutions. For example, mobile phone lenses often require ultra-precision high-speed injection molding. The design is more about the repetitive accuracy of high-speed filling, while the situation of thick-wall parts is much more complicated.

, let's take a common case of forming a low beam lens for automobiles: a PC lens with a weight of 57g, a thickness of 29mm, a hyperboloid, and a contour error of 0.02mm; The basic inspection requirements are that there should be no bubbles, black spots, flow marks, white fog or black house. Under the condition of injection molding at 265 ℃ and a thickness of 29mm, the basic shrinkage rate is calculated by 0.55% as an example, the shrinkage rate is about 0.3mm, and a shape with a thick wall is required, under the influence of flow direction, temperature difference, cooling rate, film pressure and cavity temperature after injection molding, the shrinkage rate in each direction does not change linearly. Therefore, it is difficult for ordinary injection molding processes to achieve an accuracy with a surface profile error of less than 0.02mm, which puts forward difficult requirements for the reproducibility of the injection molding process. Even if it cannot be fully controlled to the theoretical state, the recilinear accuracy of the process must be high enough. Only then can it be possible to obtain a thick-walled curved lens with high profile accuracy by means of surface shape compensation. In more than ten years of research and practice, the Echos team, A set of perfect molding process data is explored, and the performance and injection molding process control of the injection molding machine are improved and optimized, so that when the technology is applied to thick wall molding, the lens quality far exceeds the conventional molding process can be obtained. In 2021, R & D and commercial application are used for high-precision injection molding of thick-walled lenses with 1 8 holes and 16 holes, thereby greatly reducing the injection cost of the lens.

injection molding system is equipped with special plasticizing components, injection control, anaerobic plasticizing, low speed and high pressure injection molding, dynamic variable temperature injection molding, injection compression and other functions. Since 2010, it has served many automobile brands such as Mercedes-Benz, BMW, Volkswagen, Great Wall, Changan, GM, Ford, Honda, Nissan, Geely, etc.

For thick-walled transparent optical injection molding, shrinkage, flow marks and white crystals need to be effectively solved. As well as the yellowing, light transmittance, black spots, black fog and other problems of the light guide strip, the Echos team has developed a variety of solutions, such as: low-speed and high-pressure injection molding (the minimum stable adjustable speed is 0.1 mm/s, and the maximum injection pressure is as high as 4000bar), which effectively relieves the problems of glue flow pattern and record pattern during the injection molding process, at the same time, there are starvation feeding, anaerobic plasticization, injection compression, precise melt metering, low-speed injection molding, low-inertia motion control, high-pressure PVT molding and other processes. With special plasticizing components, it can effectively deal with bubbles, white mist, shrinkage and other problems. The functions of anaerobic plasticization and starvation feeding make the instant molding cycle of PC materials as high as 20min can maintain no yellow edges and no bubbles, and inhibit the generation of decomposition gas scale of raw materials, so as to improve the quality and qualification rate of products.

thick-walled injection molding system, the basic molding requirements are as follows: 1. Low speed stability. In this case, the minimum controllable speed is 0.5 mm/s;2. Plasticizing quality: no white fog, white crystal, no yellowing and high permeability; 3. The gas and moisture content in the plasticizing process are low, and the injection process is stable without gas marks, turbulence marks and bubbles; 4. In the process, the pressure switching is gentle, no impact and no shock, so as to realize the filling flow and no internal impact shear, and the process reproduction accuracy is high.

legend: comparison of common white fog control and permeability:

1. Universal transparent thick-wall optical injection molding machine series, with clamping force ranging from 40 tons to 2500 tons, is used for conventional transparent optical injection molding.

2. The double-shot optical injection molding machine series has a clamping force ranging from 240 tons to 2500 tons. On the basis of the conventional transparent optical injection molding machine, two injection tables are configured, which can quickly switch and choose to use different injection tables. The three common applicable scenarios are: A. PC or PMMA is sometimes used for injection molded optical products. When the conventional injection molding machine replaces the injection molding material, it takes a lot of time and expensive raw materials to clean the screw barrel, and it is difficult to ensure whether the cleaning is completely clean. When two sets of injection units are provided, the two barrel screws can be distinguished and applied, quickly switched, economical and efficient. Applicable scenario B: When it is difficult for products with large weight difference to share an injection molding machine, the screws of the two injection molding units are different in size, when producing products with small injection weight, switch between small products and large products with large injection screws, so as to reasonably match the size of injection screws, improve the qualified rate of products, and improve the utilization rate of equipment. At the same time, make the injection molding equipment in the workshop more flexible in scheduling and scheduling, facilitate the production arrangement of orders and improve economic benefits. Applicable scenario C: When recycled materials or color materials may be used in the mold testing stage of some products, it is convenient to distinguish and use. Genuine production uses another barrel to produce, rationally use different raw materials, and improve the economic benefits of production arrangements.

3. Multiple groups of layered injection molding systems, with clamping force ranging from 280-2500 tons, can be equipped with 2-4 injection molding units to realize high-efficiency and high-precision production of thick-walled products, such as thick-walled high-precision lenses, one machine It can realize single-layer, double-layer, three-layer, five-layer and other injection molding processes to achieve a high-efficiency production cycle, and unlike traditional two-color injection molding machines, this series of machines can be completely used as ordinary monochrome injection molding machines, the nozzle can be adjusted freely in the center and front and back deviation, realizing the injection molding operation of the mold with 1, 2, 3, 4 and 6 stations, so that the utilization rate of the machine can be fully utilized.