Injection Molding
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COC Vehicle Lamp Lens Optical Defect
Problem Phenomenon
After '2079851475616104452 of COC vehicle lamp lenses, the light pattern test is unqualified; local distortion and streaks interfere with light distribution, and are difficult to find by appearance inspection.
Cause Analysis
The optical surface of the lens is extremely sensitive to internal stress and replication accuracy; gate marks, weld lines and ejector pin marks all distort the light path; uneven mold temperature causes slight surface shape distortion.; During on-site troubleshooting, verify item by item according to this mechanism to avoid blindly adjusting the machine based only on experience
Solution
①Design the gate position and form according to optical simulation; ②use a high mold temperature, low speed, low stress process; ③mirror polish the optical surface and cool uniformly; ④include light distribution testing in full inspection.
Key Takeaway
The quality yardstick of COC optical lenses is the light pattern, not the appearance; optical simulation guides gate design; surface shape accuracy is guaranteed by mold temperature uniformity.; After confirming effectiveness, fix the parameters and practices into the work instruction to prevent recurrence
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