CN205364440U - Different chamber of LED shot -light aspherical lens injection compression heat runner mould - Google Patents

Abstract

The utility model provides an LED spotlight aspherical lens different-cavity injection compression hot runner mold. The mold is composed of a mold base, a pouring system, a guiding mechanism, a demoulding mechanism, a heating system, a compression The action of the limit spring and the limit rod keeps a certain compression distance between the movable platen and the compression plate; the compression plate is pushed to the bottom surface of the movable platen by the clamping force of the injection molding machine, so that the inserts of the movable mold are moved towards the respective lenses Partial pressure is applied to the cavity to complete precision molding. The compression plate of the compression mechanism is between the movable template and the pad, and is rigidly connected with the pad and the movable template seat plate with screws and flexibly connected with the movable template through a limit spring. The bottom gap between the compression plate and the movable template is determined by the limit Rod and limit screw to achieve. The main channel adopts hot nozzle structure, and the pouring system adopts the form of one mold and different cavities, and the melt flows to different configurations of lens cavities through the reversing mechanism. The mold has high molding precision and processing efficiency, saves energy and reduces consumption, and significantly improves the surface shape precision and optical performance of the lens.

Description

LED Spotlight Aspherical Lens Different Cavity Injection Compression Hot Runner Mold

technical field

The utility model relates to the field of injection molding processing molds for general plastics and engineering plastics, in particular to an LED spotlight aspheric lens different-cavity injection compression hot runner mold.

Background technique

As the main light shape control device of LED spotlights, the lens can not only converge the light beam, but also generate divergent light beams, which can effectively control the light emitted by the LED at various angles. Especially the aspherical lens for LED lighting has a remarkable effect in improving the imaging quality, and the design of various non-circular symmetrical spots is more flexible, making the aspheric lens for LED spotlights as a light distribution device widely used in landscape lighting, commercial lighting, industrial and mining lighting, and household lighting. Applications in lighting and other fields are becoming more and more extensive.

Aspherical lenses for LED spotlights are usually processed by injection molding of optical-grade plastics polymethyl methacrylate (PMMA) and polycarbonate (PC). The aspherical characteristics of the lens make the molding process much more difficult than ordinary spherical lenses. As an optical-grade product, lenses have strict requirements on light transmittance, surface shape accuracy, surface quality, thermal stability, refractive index, turbidity, and optical axis coaxiality. The uneven wall thickness of the aspheric lens for LED spotlights makes the lens density and refractive index distribution uneven, resulting in residual stress and birefringence, making it difficult to ensure the surface shape accuracy and optical uniformity of the lens.

The quality of LED spotlight aspheric lens is affected by many factors. Quality defects such as uneven volume shrinkage, warping deformation and large residual stress of injection molded products are especially related to the pressure holding state in the injection molding process. Injection molding is to prevent the shrinkage of the product by holding pressure. If the holding pressure is small, the shrinkage will be insufficient. If the holding pressure is high, the molecular orientation near the gate will be serious, resulting in residual stress, which will cause the product to deform and affect the accuracy. The residual stress of lens injection molding is large and widely distributed, and the birefringence value is large and unevenly distributed. The shrinkage and birefringence of injection molding affect the surface shape accuracy and imaging effect of the lens.

The LED spotlight aspheric lens processed by injection compression hot runner molding, the mold cavity is not completely closed during the injection stage, and the required injection pressure is low, which is beneficial to reduce the shearing effect between the melt and the degree of macromolecular orientation; The stage further exerts pressure on the cavity melt, and the pressure distribution in the cavity is very uniform. At the same time, the molten material state of the pouring system is effectively controlled through the hot nozzle of the main channel, the energy loss is small, the aggregate is reduced, the material utilization efficiency is high, and the molding processing cycle is short.

The LED spotlight aspheric lens is obtained by injection compression hot runner mold, which can reduce the residual stress and warping deformation of the lens, improve the warping rate, light transmittance and refractive index of the lens, save energy and reduce consumption. Due to the ever-changing surface shape and structure of different lenses, it is necessary to design an injection compression hot runner mold with a more compact structure, better compression mechanism stability, higher molding accuracy and higher efficiency for LED spotlight aspheric lenses to meet the molding accuracy and requirements of different lenses. optical performance requirements.

Utility model content

The purpose of this utility model is to provide a different cavity injection compression hot runner mold for LED spotlight aspheric lens, which can solve or reduce the uneven volume shrinkage, warping deformation and large residual stress in the injection molding process of LED spotlight aspheric lens. Surface accuracy and optical uniformity problems such as uneven refractive index distribution and birefringence phenomenon, improve the structural rationality and motion stability of the compression mechanism of the injection compression mold, and realize energy saving and consumption reduction and multi-configuration lens different-cavity molding processing.

The purpose of this utility model is achieved through the following technical solutions. LED spotlight aspheric lens different cavity injection compression hot runner mold is composed of mold base, pouring system, guiding mechanism, demoulding mechanism, heating system, compression mechanism and reversing mechanism, through the limit spring and limit rod of the compression mechanism , so that a certain compression distance is maintained between the movable platen and the compression plate, the fixed mold core and the movable mold core are in contact with each other, the movable mold core insert retains a certain compression stroke in the lens cavity, and the injection molding machine injects molten material into the cavity to complete Low-pressure filling: the compression plate is pushed to the bottom surface of the movable template by the clamping force of the injection molding machine, so that the movable mold core inserts are partially pressed to the cavity of each lens to complete the precision molding. The main channel of the pouring system adopts a hot runner, that is, the main channel hot nozzle structure is adopted to keep the molten material in the main channel in a molten state, and then the molten material is transported to the lens cavity through the cold runner and the cold gate to complete the LED injection molding process. Lamp aspheric lens different cavity injection compression hot runner molding processing.

The LED spotlight aspheric lens has structural symmetry, and has strict requirements on the uniformity of light transmittance, refractive index, and turbidity. The lens material is made of optical grade PMMA and PC, which has good light transmittance and mechanical properties. It has good dimensional stability, poor fluidity and large shrinkage rate, which can meet the molding precision and optical performance requirements of LED spotlight aspheric lenses.

The injection compression molding method of the LED spotlight aspheric lens adopts a comprehensive compression type, and the clamping force provided by the injection molding machine is used to realize the two functional requirements of mold clamping and compression. The block and the movable mold seat plate are rigidly connected with screws and flexibly connected with the movable mold plate through a limit spring, and the movable mold core insert is installed on the compression plate through screw connection. A certain gap is maintained between the compression plate and the bottom surface of the movable formwork, and the size of the gap is realized by the compression distance through the limit rod and the limit screw. After the mold is closed, the clamping force is used to push the compression plate to the bottom surface of the movable platen. When the mold is opened, the limit spring and the limit rod are used to realize the separation of the compression plate and the movable platen, thereby realizing the compression and compression of the lens cavity through the compression mechanism. force control.

The hot runner method of the LED spotlight aspheric lens adopts a hot nozzle structure, and the main channel uses a hot nozzle to replace the main channel bushing of the injection mold, and the molten material enters the runner after being heated and kept warm by the hot nozzle. The pouring system adopts the form of one mold with different cavities. The shape of the runner is S-shaped. The melt flows to the lens cavity of different configurations through the reversing mechanism. The cross-sectional shape of the runner is U-shaped, and a fan-shaped gate is set on the parting surface. , to realize the coexistence of hot runner and cold runner in the gating system.

The LED spotlight aspherical lens different-cavity injection compression hot runner mold, the cold material hole of the main channel adopts an inverted cone structure, the lens product is left on the side of the movable mold when the mold is opened, and the coagulation material of the runner is ejected by a large push rod , and two different configurations of lens products are ejected by three evenly distributed small push rods or a push tube, which realizes the smooth separation of the lens from the moving mold cavity by the demoulding mechanism. The inserts of the lens molding mold are processed separately, and then embedded in the moving mold core. The mold structure is simple and the manufacturing cost is low, which can meet the precision requirements of the optical surface of the molding lens, and obtain LED spotlight aspheric lenses with high light transmittance and low birefringence .

Compared with the existing injection molding technology, the utility model has the following advantages.

1. The LED spotlight aspheric lens mold adopts the injection compression molding method, which can reduce the residual stress and warping deformation of the molded lens, realize low-pressure injection and uniform distribution of melt pressure in the cavity, and significantly improve the surface shape accuracy of the lens and improve The warping rate, light transmittance and refractive index of the lens, high molding efficiency, energy saving and consumption reduction, meet the optical precision requirements of the lens.

2. The LED spotlight aspheric lens mold adopts the hot runner method, and the molten material state of the pouring system is effectively controlled through the hot nozzle of the main channel, the filling time is short, the filling pressure is low, the energy loss is small, the coagulation is reduced, and the material utilization efficiency is high. The molding cycle is short, the volume shrinkage of the lens is uniform and the warping deformation is small, which meets the shape accuracy requirements of the lens.

3. The compression mechanism and reversing mechanism of the LED spotlight aspheric lens different-cavity injection compression hot runner mold occupy a small space in the mold, the structure is compact, the compression distance is easy to adjust, the displacement accuracy is high, and the movement stability is good. The lens and the core and cavity of the corresponding configuration have good suitability, which can effectively improve the molding accuracy and processing efficiency of the mold.

Description of drawings

Fig. 1 is a front view of the structure of the LED spotlight aspheric lens different-cavity injection compression hot runner mold of the utility model.

Fig. 2 is a side view of the structure of the LED spotlight aspheric lens different cavity injection compression hot runner mold of the utility model.

Figure 3 is a structural diagram of a mold cavity completely closed.

Fig. 4 is a front configuration diagram of a single lens.

Fig. 5 is a rear configuration diagram of a single lens.

Fig. 6 is a front view of the three-in-one lens.

Fig. 7 is a configuration diagram of the back of the three-in-one lens.

Fig. 8 is a configuration diagram of the dynamic core.

Fig. 9 is a configuration diagram of the reversing rod.

detailed description

Below in conjunction with accompanying drawing and specific embodiment, the utility model is described in further detail.

As shown in Figures 1 and 2, the LED spotlight aspheric lens different cavity injection compression hot runner mold includes mold base, pouring system, guiding mechanism, demoulding mechanism, heating system, compression mechanism and reversing mechanism, etc., mainly by positioning Ring 1, fixed mold seat plate 2, fixed mold plate 3, leading guide sleeve 4, fixed mold core 5, movable platen 6, movable mold core 7, straight guide sleeve 8, guide post 9, compression plate 10, reset lever 11, reset Spring 12, cushion block 13, screw 14/16/17/24/31/34/37/39, movable mold seat plate 15, push plate 18, push rod fixing plate 19, small push rod 20, limit spring 21, Limit screw 22, limit rod 23, hot nozzle 25, single lens 26, reversing rod 27, single lens movable mold core insert 28, single lens core rod 29, push tube 30, core rod fixing plate 32, large push Parts such as bar 33, three-in-one lens mandrel 35, three-in-one lens moving mold core insert 36, three-in-one lens 38 are formed. During the mold closing process of the injection molding machine, the precise positioning of the movable mold part and the fixed mold part is realized by using the guide column 9 of the guiding mechanism, the leading guide sleeve 4 and the straight guide sleeve 8 . In the injection stage, through the action of the limit spring 21 and the limit rod 23 of the compression mechanism, a certain compression distance is maintained between the movable template 6 and the compression plate 10, the fixed mold core 5 and the movable mold core 7 are in contact with each other, and the movable mold core is inlaid. Parts 28 and 36 and their core rods 29 and 35 retain a certain compression stroke in the lens cavity, so that the mold cavity is not completely closed, and the injection molding machine injects molten material into the cavity to complete filling. In the compression stage, the compression plate 10 is pushed to the bottom surface of the movable template 6 by the clamping force of the injection molding machine, so that the movable mold core inserts 28 and 36 and their core rods 29 and 35 are partially applied to the cavity of the respective lenses 26 and 38. Press until the mold cavity is completely closed, as shown in Figure 3. During the mold opening process of the injection molding machine, the movable mold part is separated from the fixed mold part, and the large push rod 33, the small push rod 20 and the push tube 30 push out the runner coagulation and the lens respectively, thereby completing the different-cavity injection compression molding process of the lens. In the mold clamping process of the next working cycle of the injection molding machine, the reset rod 11 and the reset spring 12 impel the push plate 18 to return to its original position.

The single lens 26 is shown in Figures 4 and 5, and the three-in-one lens 38 is shown in Figures 6 and 7. The LED spotlight aspheric lens has structural symmetry, and has a large impact on the uniformity of light transmittance, refractive index, and turbidity. The requirements are strict, and the lens material adopts optical grade PMMA and PC, which have good light transmission and mechanical properties, good dimensional stability, poor fluidity, and large shrinkage rate, which can meet the molding accuracy and requirements of LED spotlight aspheric lenses. optical performance requirements. One end face configuration of fixed die core 5 corresponds to the front of lenses 26 and 38, and one end face configuration of movable die core inserts 28 and 36 and core rods 29 and 35 thereof corresponds to the back side of lenses 26 and 38.

The compression mechanism of the LED spotlight aspheric lens different cavity injection compression hot runner mold is mainly composed of compression plate 10, limit spring 21, limit screw 22, adjustment rod 23 and other parts. 6 and the spacer 13, and the spacer 13 and the movable mold seat plate 15 are rigidly connected with screws 16 and are flexibly connected with the movable template 6 through the limit spring 21. As can be seen from FIG. 2 , the three-in-one lens movable mold core insert 36 is connected and installed on the compression plate 10 by screws 34 , and the single lens movable mold core insert 28 is also mounted on the compression plate 10 by screws. The compression plate 10 maintains a certain gap with the bottom surface of the movable template 6, and the size of the gap is realized by the compression distance through the stop rod 23 and the stop screw 22. After the mold is closed, the clamping force is used to push the compression plate 10 to the bottom surface of the movable platen 6. When the mold is opened, the limit spring 21 and the limit rod 23 are used to separate the compression plate 10 from the movable platen 6, and the length of the limit rod 23 is changed. The maximum compression distance and the restriction on the return stroke can be adjusted, so that the compression of the lens cavity and the control of the compression force can be realized through the compression mechanism. In the compression stage, by applying a certain compression force to the movable mold core insert and its core rod, the molten material in the cavity will produce a counterflow, so that the molten material in the cavity will be further adhered to the surface of the cavity, which is very important for improving the surface shape accuracy of the lens. It is beneficial, and at the same time effectively reduces the residual stress and refractive index changes caused by shrinkage.

As shown in Figure 2, the gating system of the LED spotlight aspheric lens different-cavity injection compression hot runner mold is composed of a hot runner and a cold runner. The heating and heat preservation of the nozzle 25 enters the runner channel through the fixed mold core 5, the pressure loss of the melt transmission is small, and the generation of coagulation at the main channel is avoided. The fraction runners are connected without gate scarring on the lens optical surface. From the configuration of the moving mold core 7 in Figure 8, it can be known that the gating system adopts the form of one mold with different cavities, and the shape of the runner is S-shaped. The flow of the melt to the lens cavity of different configurations is controlled by the reversing mechanism. U-shaped, a fan gate is set on the parting surface, and the heating system adopts a straight-through pipeline structure and hot oil medium, which can effectively prevent warping deformation and residual stress of the lens, and is beneficial to PMMA and PC plastic lenses with poor fluidity Molding processing. At the end of the S-shaped runner, there is a certain length of cold material cavity, so that the cold material from the hot nozzle 25 of the hot runner to the cavity can enter here through the runner to prevent the cooled melt from directly entering the lens cavity. Moreover, the molten material passing through the S-shaped runner can slow down its direct impact on the lens cavity, making the filling process of the molten material as smooth as possible, and effectively improving the molding accuracy and optical performance of the lens. From Fig. 9 and in conjunction with Fig. 8, it can be seen that the reversing mechanism composed of the reversing rod 27 with the inner hexagonal head can rotate the reversing rod 27 by 180° by rotating the hexagonal head of the reversing rod 27, so that it can be The upper runner is aligned with the lens cavity of one configuration to the lens cavity of another configuration, so as to achieve the purpose of controlling the flow of the melt to the lens cavity of different configurations.

The demoulding mechanism of the LED spotlight aspheric lens different cavity injection compression hot runner mold is mainly composed of a push plate 18, a push rod fixing plate 19, a large push rod 33, a small push rod 20, a push tube 30, a reset rod 11, and a reset spring 12 The cold material cavity of the main channel adopts an inverted cone structure, and the lens product stays on the side of the movable mold when the mold is opened. From Fig. 1 and Fig. 2 in combination with Fig. 8, it can be seen that the coagulant in the runner channel is ejected by a large push rod 33 through the core of the reversing rod 27, and the three-in-one lens 38 product is ejected by three evenly distributed small push rods 20 Ejection, the single lens 26 product is ejected by a push tube 30, for the convenience of fixing, all push rods or push tubes adopt an integral structure with a shoulder to realize the smooth separation of the lens from the moving mold cavity by the demoulding mechanism.

In summary, the utility model adopts an LED spotlight aspheric lens different-cavity injection compression hot runner mold that combines the injection compression molding method and the hot runner method. The compression mechanism and the reversing mechanism are compact in structure, and the compression distance is easy to adjust. Good motion stability, good adaptability to lenses with different curved surfaces and corresponding configurations of cores and cavities, and the residual stress and warping deformation of the molded lenses are small, which can realize low-pressure injection and uniform melt pressure in the cavity distribution, improve the warping rate, light transmittance and refractive index of the lens, high molding efficiency, energy saving, less energy loss, high material utilization efficiency, short molding processing cycle, to meet the molding accuracy and processing efficiency of the mold and the optical performance of the lens Require.

Claims (5)

1. a LED spotlight non-spherical lens different chamber injection compression hot runner mould; it is characterized in that: mould is made up of mould bases, running gate system, guiding mechanism, mould emptier, heating system, compression mechanism and changement; by compressing limit spring and the gag lever post effect of mechanism; make to keep between moving platen and compression plate certain compression distance; fixed mold core and mavable module core contact with each other; mavable module core mold insert retains certain compression travel in lens die cavity, and injection machine completes low pressure to cavity injection melt and fills；Compression plate is pushed the bottom surface of moving platen to so that mavable module core mold insert has pressed to the die cavity local of respective lens precise forming by the clamp force of injection machine.

2. LED spotlight non-spherical lens according to claim 1 different chamber injection compression hot runner mould, it is characterised in that: LED spotlight non-spherical lens has structural symmetry, and lens material adopts optical grade PMMA, PC, has good light transmission and mechanical property.

3. LED spotlight non-spherical lens according to claim 1 different chamber injection compression hot runner mould, it is characterized in that: the compression plate of compression mechanism is between moving platen and cushion block, and be rigidly connected with cushion block and Bottom clamp plate screw and flexibly connected by limit spring with moving platen, mavable module core mold insert is connected by screw and is arranged on compression plate；The bottom surface of compression plate and moving platen keeps certain interval, and its gap length is realized by gag lever post and stop screw by compression distance；Utilize clamp force to push compression plate the bottom surface of moving platen to after mould Guan Bi, during mold open, utilize limit spring and gag lever post to realize separating of compression plate and moving platen.

4. LED spotlight non-spherical lens according to claim 1 different chamber injection compression hot runner mould, it is characterized in that: the hot nozzle of sprue replaces the sprue bush of injection molding, running gate system adopts the form in a different chamber of mould, sub-runner is shaped as S type, control melt by changement and flow to the lens die cavity of various configuration, sub-runner cross sectional shape selects U-shaped, offers fan gate on die joint, it is achieved the hot flow path of running gate system and cold runner coexist.

5. LED spotlight non-spherical lens according to claim 1 different chamber injection compression hot runner mould; it is characterized in that: sprue cold slug well adopts inverted cone-shaped structure; during die sinking, lens articles stays dynamic model side; the solidifying material of sub-runner is ejected by a big push rod; and the lens articles of two various configurations is ejected by three equally distributed little push rods or an ejector sleeve, it is achieved mould emptier to lens by the smooth and easy separation of dynamic model die cavity.