期刊
出版社
ELSEVIER SCIENCE INC
DOI: 10.1016/j.precisioneng.2020.09.026
关键词
Optics; Roughness; Process monitoring; Residual stress; Injection moulding
类别
资金
- China Scholarship Council
- National Natural Science Foundation of China [61675149]
- Science Foundation Ireland (SFI) [15/RP/B3208]
- '111' project
- Ministry of Education of China [B07014]
This study demonstrates that variotherm-assisted microinjection moulding can significantly reduce residual stresses, improve geometric accuracy and surface quality of microlenses. Machine settings and screw movements are crucial in the replication process. Compared to conventional microinjection moulding conditions, the residual stress level and uniformity of the microlens array can be improved by adjusting the warm circuit temperature and switching timing.
Injection moulding is ubiquitous in the production of plastic optical components, the functionality of which depends on minimising residual stress and on precisely replicating surface forms. In this study, variotherm-assisted microinjection moulding is used to manufacture a practical microlens array designed for light-field applications in order to achieve satisfactory geometric accuracy, surface quality and stress birefringence of the microlenses, all of which are difficult to achieve by conventional microinjection moulding. Based on in-line process monitoring and a comprehensive evaluation regarding the quantitative and qualitative aspects of the aforementioned factors, the replication is shown to correlate well with machine settings and dynamic machine responses. Screw movements are found to be crucial in the replication process. Compared to an optimised conventional microinjection moulding condition, the general residual stress level and uniformity of the microlens array area are improved by 5.08% and 88.11%, respectively, when the warm circuit temperature is 135 degrees C and enhanced by 2.73% and 84.32%, respectively, by a delayed switch from the warm circuit to the cold circuit. It is concluded that variotherm-assisted microinjection moulding can significantly reduce residual stresses while maintaining excellent geometric accuracy and surface quality.
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