A feasible injection molding technique for the manufacturing of large diameter aspheric plastic lenses

Shieh, Jiann; Wang, Luke K.; Ke, Shih-Ying

doi:10.1007/s10043-010-0074-8

Cited by 16 publications

(12 citation statements)

References 5 publications

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“…Therefore, the level of injection pressure should be adjusted to smaller values. The IMPP and levels for 3 4 full factorial experiments are shown in Table 5. Similarly, the experiments were arranged in random order, and the experimental results are shown in Table 6.…”

Section: Building Bpnn and M-svr Modelmentioning

confidence: 99%

“…Pazos et al [1] estimated the ultimate thickness of PC biconcave and biconvex lenses using the CAE tool and evaluated the quality of the optical lens based on the number and location of weld lines and air-traps. J. Wen and P. Wen 2 Mathematical Problems in Engineering [2], Bensingh et al [3], and Shieh et al [4] optimized PMMA aspheric lens, bi-aspheric lens, and large diameter aspheric plastic lens, respectively, through design of experiments (DOE) and numerical simulation, reducing the volumetric shrinkage of the lens effectively. With the linear shrinkage of a specific point of the optical lens as an optimization objective, Hu and Cui [5] studied the effect of holding pressure and gate size on the objective.…”

Section: Introductionmentioning

confidence: 99%

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Multiobjective Optimization of Injection Molding Process Parameters for the Precision Manufacturing of Plastic Optical Lens

Liu

Chen

Lin

et al. 2017

Mathematical Problems in Engineering

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Injection molding process parameters (IMPP) have a significant effect on the optical performance and surface waviness of precision plastic optical lens. This paper presents a set of procedures for the optimization of IMPP, with haze ratio (HR) reflecting the optical performance and peak-to-valley 20 (PV 20 ) reflecting the surface waviness as the optimization objectives. First, the orthogonal experiment was carried out with the Taguchi method, and the results were analyzed by ANOVA to screen out the IMPP having a significant effect on the objectives. Then, the 3 4 full-factor experiment was conducted on the key IMPP, and the experimental results were used as the training and testing samples. The BPNN algorithm and the M-SVR algorithm were applied to establish the mapping relationships between the IMPP and objectives. Finally, the multiple-objective optimization was performed by applying the nondominated sorting genetic algorithm (NSGA-II), with the built M-SVR models as the fitness function of the objectives, to obtain a Pareto-optimal set, which improved the quality of plastic optical lens comprehensively. Through the experimental verification on the optimization results, the mean prediction error (MPE) of HR and PV 20 is 7.16% and 9.78%, respectively, indicating that the optimization method has high accuracy.

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Section: Building Bpnn and M-svr Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Multiobjective Optimization of Injection Molding Process Parameters for the Precision Manufacturing of Plastic Optical Lens

Liu

Chen

Lin

et al. 2017

Mathematical Problems in Engineering

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“…Not only does it result in extended cooling time, but it also results in uneven shrinkage that causes the lens profile to deform. In addition, the accumulation of heat in the components affects the productivity and optical properties of the plastic lenses …”

Section: Introductionmentioning

confidence: 99%

“…For high‐precision injection‐molded lenses, the surface profile accuracy can be achieved by conventional injection molding (CIM) and injection compression molding (ICM). For example, the CIM application of the Taguchi method with mold error compensation and aspheric analysis software (AUU) can improve the replication rate of the microstructure and reduce the surface profile error . Regarding the main parameters affecting the surface profile, Tsai et al .…”

Section: Introductionmentioning

confidence: 99%

Multilayer injection molding of high‐profile convex lens

Shen

Chen²,

Huang³

2019

J of Applied Polymer Sci

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The use of injection molding to produce a convex lens of a high thickness and a high proportion of the component thickness requires not only a long cooling time but also results in a low production efficiency and a low yield. In particular, the heat concentration in thick regions can create high shrinkage and create poor surface geometry in these lenses. Multilayer injection molding (MIM) has reduced the cycle time and also improved the geometrical accuracy of thick parts, and thus it has drawn attention in recent years. This study evaluated the feasibility of MIM to produce a convex lens having a high thickness and a high thickness ratio, in which a thick optical lens would be made of a plurality of thin layers. In this study, conventional injection molding (CIM), two-layer IM, and threelayer IM were evaluated empirically to explore the effects of various molding combinations on surface contours accuracy, cycle time, residual stress, and lens transmittance. In the comparison, the three-layer IM significantly reduced the surface profile error to 0.015 mm (CIM was 0.1 mm) and reduced the surface profile error to 30%. Moreover, uniformity of the shrinkage distribution and good surface profile accuracy can be obtained.

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“…Many research results have indicated that the parameters for the injection molding process have significant effects on the quality of the products [6][7][8][9]; the effects were also observed in polymer lenses [7][8][9]. The surface profile measurements for optical elements are generally implemented on ZYGO laser interferometers because of their convenience and accuracy [10].…”

Section: Introductionmentioning

confidence: 99%

Determination of injection molding process windows for optical lenses using response surface methodology

Tsai

Wang

2014

Appl. Opt.

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This study focuses on injection molding process window determination for obtaining optimal imaging optical properties, astigmatism, coma, and spherical aberration using plastic lenses. The Taguchi experimental method was first used to identify the optimized combination of parameters and significant factors affecting the imaging optical properties of the lens. Full factorial experiments were then implemented based on the significant factors to build the response surface models. The injection molding process windows for lenses with optimized optical properties were determined based on the surface models, and confirmation experiments were performed to verify their validity. The results indicated that the significant factors affecting the optical properties of lenses are mold temperature, melt temperature, and cooling time. According to experimental data for the significant factors, the oblique ovals for different optical properties on the injection molding process windows based on melt temperature and cooling time can be obtained using the curve fitting approach. The confirmation experiments revealed that the average errors for astigmatism, coma, and spherical aberration are 3.44%, 5.62%, and 5.69%, respectively. The results indicated that the process windows proposed are highly reliable.

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A feasible injection molding technique for the manufacturing of large diameter aspheric plastic lenses

Cited by 16 publications

References 5 publications

Multiobjective Optimization of Injection Molding Process Parameters for the Precision Manufacturing of Plastic Optical Lens

Multiobjective Optimization of Injection Molding Process Parameters for the Precision Manufacturing of Plastic Optical Lens

Multilayer injection molding of high‐profile convex lens

Determination of injection molding process windows for optical lenses using response surface methodology

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