• Journal of the Korean Society for Precision Engineering
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• v.22 no.12 s.177
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• pp.100-107
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• 2005

The present work covers a new ray tracing scheme of an injection-molded plastic lens linked with finite element analysis fur injection molding processes. The traditional ray tracing schemes have been based on the assumption that optical property of the lens is homogeneous throughout the entire volume. However, this assumption is quite unrealistic for injection-molded plastic lenses since material properties vary at every point due to injection molding effects. In order to consider non-homogeneous property of a lens, a modified ray tracing method is proposed in connection with finite element analysis of injection molding. Through the analysis of the injection molding process, the distribution of refractive indices can be obtained. This information is then utilized in the proposed ray tracing scheme based on finite element meshes so as to take into account variation of the refractive indices. The effect of mold temperature is also investigated through finite element analysis, and the relevant optical quality is evaluated through the proposed ray tracing simulation.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.16 no.3
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• pp.117-124
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• 2007

In order to operate CD and DVD compatibly in a pickup system, the objective lens comprise diffractive optical element(DOE) zone and aspheric curvature on its lens surface. The DOE objective lens is effective to simplify this dual-purpose pickup system of the 655nm and 785nm wavelength by using only one lens, but requires more precision manufacturing process and system due to the complicated shape. This paper presents the overall manufacturing process of this objective lens and describes main parameters in each process, for the correction of the aspheric surface in its core, the shrinkage compensation after injection molding, and the uniformity compensation by adjusting molding conditions.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.6 s.171
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• pp.55-60
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• 2005

This paper has been focused in developing of plastic lens with ultra-precision and low birefringence ability using by injection molding simulation tools. The simulation tools, $3D-Timon^{TM}\;and\;Asu-Mold^{TM}$ were applied to visualize indirectly the flow pattern of melted polymer enter the mould and the simulation results are verified as compared with the experimental results. Birefringence and polarized light generated in injection molding process was also calculated for each injection conditions and compared with .the pictures of experimented optical lens go through the polarized light plates device. A spherical radius of plastic optical lens transcribed from profile of mould core surface was measured to estimate the geometrical accuracy fer the each injection conditions. It is confirmed that the simulation results about flow pattern and polarized light area coincided in experimental results. It is known that increasing in thickness shrinkage at center of lens, the spherical radius is larger from comparing the graph measured spherical radius and the thickness shrinkage at center of lens

• 한국금형공학회:학술대회논문집
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• 2008.06a
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• pp.143-148
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• 2008

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, a full-3d simulation based on solid elements has been reported as a reliable approach. The present work covers three-dimensional injection molding simulation and relevant deformation analysis of an injection molded plastic lens based on 3d solid elements. Numerical analyses have been applied to the injection molding processes of three aspheric lenses for an image sensing module of a mobile phone. The reliability of the proposed approach has been verified in comparison with the experimental results.

• Journal of the Korean Society for Precision Engineering
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• v.31 no.11
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• pp.1031-1040
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• 2014

In this paper, a new condition diagnosis algorithm for the lens injection molding process using various features extracted from cavity pressure, nozzle pressure and screw position signals is developed with the aid of probability neural network (PNN) method. A new feature extraction method is developed for identifying five (5), seven (7) and two (2) critical features from cavity pressure, nozzle pressure and screw position signals, respectively. The node energies extracted from cavity and nozzle pressure signals are also considered based on wavelet packet decomposition (WPD). The PNN method is introduced to build the condition diagnosis model by considering the extracted features and node energies. A series of the lens injection molding experiments are conducted to validate the model, and it is demonstrated that the proposed condition diagnosis model is useful with high diagnosis accuracy.

• Design & Manufacturing
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• v.6 no.1
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• pp.12-17
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• 2012

In order to produce high-quality optical components, aspheric lenses have been widely applied in recent years. An aspheric lens consists of aspheric surfaces instead of spherical ones, which causes difficulty in the design process as well as the manufacturing procedure. Although injection molding is widely used to fabricate optical lenses owing to its high productivity, there remains lots of difficulty to determine appropriate mold design factors and injection molding parameters. In the injection molding fields, computer simulation has been effectively applied to analyze processes based on the shell analysis so far. Considering the geometry of optical lenses, a full-3d simulation based on solid elements has been reported as a reliable approach. The present work covers three-dimensional injection molding simulation and relevant deformation analysis of an injection molded plastic lens based on 3d solid elements. Numerical analyses have been applied to the injection molding processes of three aspheric lenses for an image sensing module of a mobile phone. The reliability of the proposed approach has been verified in comparison with the experimental results.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.18 no.11
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• pp.1-8
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• 2019

In this study, we design the feed system and process conditions for a lamp garnish lens of an automobile. For this purpose, four design alternatives are presented and injection molding simulation analyses are performed. The optimal feed system is selected by considering the formability of the product and the cost of mold manufacture. The product formability is assessed by the weld line, warpage, sink mark and the maximum injection pressure, whereas the mold-making cost is estimated by the number of valve gates in the hot runner system. To improve the product formability, process conditions are optimized using an experimental design approach named one-factor-at-a-time. No weld line is generated as a result of the optimization. In addition, it is found the warpage and sink mark are reduced while the maximum injection pressure is increased, compared with those before the optimization.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2004.10a
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• pp.280-283
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• 2004

Micro-lens patterned micro-mold fabrication method for Light Guiding Plate(LGP), kernel part of LCD-BLU(Back Light Unit), was presented. Instead of erosion dot pattern for LGP optical design, micro-lens pattern, fabricated by LIGA-reflow process, was applied. Optical pattern design method was also developed not only for negative pattern LGP, but also positive pattern LGP. During injection molding process, experimental study was conducted to improve replication quality and brightness of ${\sim}50um$ micro-lens pattern mold. The effect of mold temperature for the replication quality of micro-lens array was studied.

• Transactions of the Society of Information Storage Systems
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• v.6 no.1
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• pp.37-40
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• 2010

Fresnel lens is a kind of refractive optical lens with various advantages. It has nearly flat shaped optical lens that has small mass. Fresnel lens has number of applications in the compact optical systems. Recently, demands of high quality Fresnel lens for small size optical systems such as illumination units, compact imaging systems, display units, information storage systems, optical detecting units had increased rapidly. Conventional manufacturing process of high quality Fresnel lens is direct machining. However, it is not suitable for mass production because of high cost and long cycle time. Replication method can provide cost effective mass production process. However, there are various issues about replication of Fresnel lens. Fresnel lens has number of sharp blade shape prism. In the replication process, this blade shape causes defects that can affect optical efficiency. In this study, replication processes; injection molding process and UV imprinting process, were developed and evaluated using Fresnel lens that has maximum pattern height of $250\;{\mu}m$ and aspect ratio of 1.5.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.1
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• pp.95-100
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• 2018

This study has focused on the weld-line and birefringence reduction of a plastic optic lens using over and CAE analysis in injection compression molding. A concave lens, which has a thin thickness in the center and a large difference in thickness between the center and the periphery, often causes weld-line defects during injection molding. CAE analysis has been applied to optimize the overflow design in order to reduce the weld-line defects and the polarization defects. To reduce the weld line and birefringence defects, overflow design and application using CAE analysis show that the measured birefringence values of the specimens before the overflow application were 46.8nm and 36.9nm, and the values after the over-flow application were 13.6nm and 14.0nm. From the experimental results, it is confirmed that birefringence is greatly improved when overflow is applied.