Ultraprecision Mass Fabrication of Aspherical Fresnel Lens by Glass Molding Press

2011 ◽  
Vol 325 ◽  
pp. 713-718 ◽  
Author(s):  
Tian Feng Zhou ◽  
Ji Wang Yan ◽  
Jun Masuda ◽  
Tunemoto Kuriyagawa
Keyword(s):  
High Efficiency ◽  
Fresnel Lens ◽  
Molding Process ◽  
Diamond Cutting ◽  
Glass Molding ◽  
Machining Center ◽  
Molding Condition ◽  
Glass Lens ◽  
Lens Surface ◽  
Plating Layer

Glass molding press (GMP) was applied to the fabrication of glass aspherical Fresnel lens for high-efficiency mass production. A pair of molds for the Fresnel lens was precisely fabricated on the Nickel Phosphorous (Ni-P) plating layer by the single diamond cutting with multi-axis machining center. A kind of low transition temperature (Tg) glass was heated to several tens degree centigrade above its Tg and compressed between the two molds. In this way, the shape of the mold was replicated to the glass lens surface. The molding process was simulated by finite element method (FEM), and the molding condition was optimized to minimize the residual stress.

Size Effects on Transferability and Mold Change of Glass Molding Press for Microgrooves

2012 ◽  
Vol 497 ◽  
pp. 235-239 ◽  
Author(s):  
Tian Feng Zhou ◽  
Ji Wang Yan ◽  
Tunemoto Kuriyagawa
Keyword(s):  
Size Effects ◽  
Glass Surface ◽  
Diamond Cutting ◽  
Glass Molding ◽  
Comparison Research ◽  
Plating Layer

Glass molding press (GMP) was applied to the fabrication of 3 kinds of microgrooves with different pitches on the glass surface. The size effects of microgroove fabrication on the Nickel Phosphorous (Ni-P) plating layer by diamond cutting were experimentally tested, and then, the size effects of microgroove fabrication by GMP using the Ni-P mold were experimentally tested. Finally, the changes of the Ni-P mold after GMP by 100 shots were compared with the microgroove mold before GMP, and the size effects of the mold change were discussed. By the comparison research of microgroove fabrication with different pitches, it suggests a way to create microgrooves with even smaller size.

A Study on Injection Molding Analysis and Structural Analysis with Truck Brake Pedal

2013 ◽  
Vol 535-536 ◽  
pp. 430-433
Author(s):  
Chul Woo Park ◽  
Seong Ho Seo
Keyword(s):  
Injection Molding ◽  
High Efficiency ◽  
Low Cost ◽  
Fem Simulation ◽  
High Strength ◽  
Injection Molding Process ◽  
Brake Pedal ◽  
Molding Process ◽  
Molding Condition ◽  
Plastic Parts

Injection molding process one of the most important methods to produce plastic parts with high efficiency and low cost. Today, Injection molded parts have been increased dramatically the demand for high strength and quality applications. In this study, truck brake pedal is made of Cast iron and plastic materials to replace the frame for the optimization process that minimizes the runner and the gate dimension will determine the size and shape. Runner and gate dimensions of change based on availability of the product. I will discuss the injection molding. This report investigates that the optimum injection molding condition for minimum of runner and gate position. The FEM Simulation CAE tool, MOLDFLOW, is used for the analysis of injection molding process.

Design of Protective Coatings for Glass Lens Molding

2007 ◽  
Vol 364-366 ◽  
pp. 655-661 ◽  
Author(s):  
Kung Jeng Ma ◽  
H.H. Chien ◽  
W.H. Chuan ◽  
Choung Lii Chao ◽  
K.C. Hwang
Keyword(s):  
High Temperature ◽  
Protective Coatings ◽  
Optical Glass ◽  
Low Cost ◽  
Interface Reaction ◽  
Molding Process ◽  
Ceramic Substrates ◽  
Glass Molding ◽  
Operation Temperature ◽  
Glass Lens

The glass molding process is considered to have a great potential for the mass production of aspherical glass lenses with high precision and low cost. However, glass molding has a serious problem of mold sticking with glass which needs to be resolved. This research investigates the interface reaction between glass and mold by high temperature wetting experiment, which provides the reference for the designing anti-stick coatings. The SUMITA K-PSK200 optical glass gobs with low Tg were used in this study. The influence of operation temperature, ambient gas, substrate materials, and thin film composition on wettability of glass at high temperature were studied. The results show that the higher the temperature, the smaller the wetting angle between glass gob and substrate could be observed. This indicates that severe interface chemical reaction occured and resulted in the loss of transparency in glass appearance. The wetting experiment in nitrogen ambient improved the sticking situation. The combination of chemically stable substrates and coatings, such as Sapphire (substrate) / GaN (film) and Glass (substrate) / Al2O3 (film) can achieve the best antistick propose. The precious metal films, such as Pt, Ir, coated on the ceramic substrates can effectively reduce the interface reaction between the glass and substrates.

Numerical Simulation on Two-Step Isothermal Glass Lens Molding

2010 ◽  
Vol 126-128 ◽  
pp. 564-569 ◽  
Author(s):  
Shao Hui Yin ◽  
Ke Jun Zhu ◽  
Yu Fang Wang ◽  
Feng Jun Chen ◽  
Yu Wang
Keyword(s):  
Residual Stress ◽  
Strain Distribution ◽  
High Efficiency ◽  
Stress And Strain ◽  
Key Factors ◽  
Molding Process ◽  
Element Simulation ◽  
Glass Lens ◽  
Lens Molding ◽  
Stress And Strain Distribution

Glass lens molding is an effective approach to produce precision micro aspheric glass lens at high efficiency. In this paper, a new two-step isothermal glass molding process was proposed. The mechanisms of new molding process were analyzed. Finite element simulation was conducted to analyze the key factors such as the pressing load, die damage, molding time and residual stress of lens during the traditional molding and the two-step isothermal molding. The results showed that the two-step isothermal glass lens molding process may decrease residual stress and improve stress and strain distribution. Furthermore, prolong the service life of die.

Design and Evaluation of the Fresnel-Lens Based Solar Concentrator System Through a Statistical-Algorithmic Approach

2018 ◽  
Author(s):  
Hassan Qandil ◽  
Weihuan Zhao
Keyword(s):  
High Temperature ◽  
High Efficiency ◽  
Incident Light ◽  
Thermal Analyses ◽  
Solar Spectrum ◽  
Chromatic Aberration ◽  
Fresnel Lens ◽  
Optimum Number ◽  
Solar Concentrator ◽  
Receiver System

A novel non-imaging Fresnel-lens-based solar concentrator-receiver system has been investigated to achieve high-efficiency photon and heat outputs with minimized effect of chromatic aberrations. Two types of non-imaging Fresnel lenses, a spot-flat lens and a dome-shaped lens, are designed through a statistical algorithm incorporated in MATLAB. The algorithm optimizes the lens design via a statistical ray-tracing methodology of the incident light, considering the chromatic aberration of solar spectrum, the lens-receiver spacing and aperture sizes, and the optimum number of prism grooves. An equal-groove-width of the Poly-methyl-methacrylate (PMMA) prisms is adopted in the model. The main target is to maximize ray intensity on the receiver’s aperture, and therefore, achieve the highest possible heat flux and output concentration temperature. The algorithm outputs prism and system geometries of the Fresnel-lens concentrator. The lenses coupled with solar receivers are simulated by COMSOL Multiphysics. It combines both optical and thermal analyses for the lens and receiver to study the optimum lens structure for high solar flux output. The optimized solar concentrator-receiver system can be applied to various devices which require high temperature inputs, such as concentrated photovoltaics (CPV), high-temperature stirling engine, etc.

Solar Thermophotovoltaic Converters Based on Tungsten Emitters

2006 ◽  
Vol 129 (3) ◽  
pp. 298-303 ◽  
Author(s):  
V. M. Andreev ◽  
A. S. Vlasov ◽  
V. P. Khvostikov ◽  
O. A. Khvostikova ◽  
P. Y. Gazaryan ◽  
...  
Keyword(s):  
Band Gap ◽  
High Efficiency ◽  
Radiation Spectrum ◽  
Cost Effective ◽  
Fresnel Lens ◽  
Photocurrent Density ◽  
Back Side ◽  
High Concentration ◽  
Emitter System ◽  
Solar Powered

Results of a solar thermophotovoltaic (STPV) system study are reported. Modeling of the STPV module performance and the analysis of various parameters influencing the system are presented. The ways for the STPV system efficiency to increase and their magnitude are considered such as: improvement of the emitter radiation selectivity and application of selective filters for better matching the emitter radiation spectrum and cell photoresponse; application of the cells with a back side reflector for recycling the sub-band gap photons; and development of low-band gap tandem TPV cells for better utilization of the radiation spectrum. Sunlight concentrator and STPV modules were designed, fabricated, and tested under indoor and outdoor conditions. A cost-effective sunlight concentrator with Fresnel lens was developed as a primary concentrator and a secondary quartz meniscus lens ensured the high concentration ratio of ∼4000×, which is necessary for achieving the high efficiency of the concentrator–emitter system owing to trap escaping radiation. Several types of STPV modules have been developed and tested under concentrated sunlight. Photocurrent density of 4.5A∕cm2 was registered in a photoreceiver based on 1×1cm2GaSb cells under a solar powered tungsten emitter.

Precision Grinding of Structured Tungsten Carbide Mold

2012 ◽  
Vol 497 ◽  
pp. 15-19 ◽  
Author(s):  
Hirofumi Suzuki ◽  
Tatsuya Furuki ◽  
Mutsumi Okada ◽  
Yutaka Yamagata ◽  
Shinya MORITA
Keyword(s):  
Tungsten Carbide ◽  
Power Efficiency ◽  
Fresnel Lens ◽  
Rare Metal ◽  
Diamond Wheel ◽  
Precision Grinding ◽  
Form Accuracy ◽  
Molding Method ◽  
Grinding Method ◽  
Glass Lens

Demands of glass Fresnel lens is increasing in solar panel in order to increase power efficiency. Glass lens is usually molded by glass molding method with tungsten carbide molds. In this study, large Fresnel lens molds made of tungsten carbide are tested to be ground by simultaneous 2-axis (Y, Z) controlled grinding method. The resinoid bonded diamond wheel was trued with a rare metal truer to improve the sharpness of the wheel edge. In the grinding test of the tungsten carbide mold, a form accuracy of less than 0.8 μm P-V and surface roughness of 18 nm Rz were obtained, and it is clarified that the proposed grinding method is useful for the Fresnel grinding.

scholarly journals The glass-molding process for planar-integrated micro-optical component

2011 ◽  
Vol 18 (1) ◽  
pp. 96-98 ◽  
Author(s):  
Chien-Yao Huang ◽  
Jyh-Rou Sze ◽  
Kuo-Cheng Huang ◽  
Chao-Hui Kuo ◽  
Shih-Feng Tseng ◽  
...  
Keyword(s):  
Optical Component ◽  
Molding Process ◽  
Glass Molding

Application of Orthogonal Test in Numerical Simulation of Glass Lens Molding

2012 ◽  
Vol 497 ◽  
pp. 245-249
Author(s):  
Dao Cheng Zhang ◽  
Ke Jun Zhu ◽  
Yong Jian Zhu ◽  
Shao Hui Yin ◽  
Jian Wu Yu
Keyword(s):  
Process Parameters ◽  
Orthogonal Experiment ◽  
Fem Simulation ◽  
Orthogonal Test ◽  
Test Method ◽  
Testing Time ◽  
Molding Process ◽  
Glass Lens ◽  
Lens Molding ◽  
Process Factors

Glass lens molding is a high-volume fabrication method for producing optical components. In this paper, combined with the orthogonal test method and finite element method (FEM) simulation, the coupled thermo-mechanical analysis was carried out to analyze the key process factors. In order to reduce the testing time, an orthogonal test with three sets of level factors and three parameters is conducted to obtain the optimal molding process parameters. The result shows that the most significant parameter is molding velocity, the other effect parameters are molding temperature and friction coefficient. According to the previous analysis of orthogonal experiment, it is shown that the best optimal finishing process parameters were A2B1C1.

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