Fabrication of Plano-Concave Plastic Lens by Novel Injection Molding Using Carbide-Bonded Graphene-Coated Silica Molds

Xiaohua Liu, Lin Zhang, Wenchen Zhou, Tianfeng Zhou, Jianfeng Yu, L. James Lee, Allen Y. Yi*

*此作品的通信作者

研究成果: Article同行評審

6 引文 斯高帕斯(Scopus)

摘要

Injection molding of plastic optical lenses prevails over many other techniques in both efficiency and cost; however, polymer shrinkage during cooling, high level of uneven residual stresses, and refractive index variations have limited its potential use for high precision lens fabrication. In this research, we adopted a newly developed strong graphene network to both plano and convex fused silica mold surfaces and proposed a novel injection molding with graphene-coated fused silica molds. This advanced injection molding process was implemented in the molding of polymer-based plano-concave lenses resulting in reduced polymer shrinkage. In addition, internal residual stresses and refractive index variations were also analyzed and discussed in detail. Meanwhile, as a comparison of conventional injection mold material, aluminum mold inserts with the same shape and size were also diamond machined and then employed to mold the same plano-concave lenses. Finally, a simulation model using moldex3d was utilized to interpret stress distributions of both graphene and aluminum molds and then validated by experiments. The comparison between graphene-coated mold and aluminum mold reveals that the novel injection molding with carbide-bonded graphene-coated fused silica mold inserts is capable of molding high-quality optical lenses with much less shrinkage and residual stresses with a more uniform refractive index distribution.

原文English
文章編號081011
期刊Journal of Manufacturing Science and Engineering, Transactions of the ASME
141
發行號8
DOIs
出版狀態Published - 1 8月 2019

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