CN110612197B - Method and apparatus for automatically injecting mold for optical material monomer - Google Patents
Method and apparatus for automatically injecting mold for optical material monomer Download PDFInfo
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- CN110612197B CN110612197B CN201880030730.2A CN201880030730A CN110612197B CN 110612197 B CN110612197 B CN 110612197B CN 201880030730 A CN201880030730 A CN 201880030730A CN 110612197 B CN110612197 B CN 110612197B
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- monomer
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- monomer solution
- liquid level
- injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/0048—Moulds for lenses
- B29D11/00528—Consisting of two mould halves joined by an annular gasket
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/00432—Auxiliary operations, e.g. machines for filling the moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00009—Production of simple or compound lenses
- B29D11/0048—Moulds for lenses
- B29D11/00538—Feeding arrangements
Abstract
The invention is to wind a tape around the periphery of a mold, then inject a monomer solution into a cavity formed between the mold and the tape, shoot the liquid level change of the monomer solution injected into the cavity by a visual recognition system so as to accurately control the injection amount of the monomer solution by the visual recognition system, compare the shot liquid level change with the liquid level change shape of each stage of the monomer solution stored in advance, when the liquid level change shape of the injected monomer solution is consistent with the liquid level change shape of the monomer stored in advance, a controller can adjust the injection amount of the injector according to each stage and inject the monomer solution into the cavity.
Description
Technical Field
The present invention relates to a method and an apparatus for manufacturing an optical material by injecting a monomer solution into a cavity formed between a pair of molds whose outer peripheries are sealed, and more particularly, to a method and an apparatus for automatically injecting a monomer for an optical material into a mold, which can accurately control an injection amount of the monomer in accordance with a change in a liquid level while confirming a change in the liquid level of the injected monomer in real time by a visual recognition system.
Background
Among optical materials, plastic lenses have advantages of being lighter and less likely to be broken than glass lenses, and having excellent processability. There has recently been a trend to use more plastic lenses than glass lenses. The plastic lens is produced by injecting a polymer compound called monomer (monomer) into a mold, solidifying the polymer compound, and then performing appropriate post-processing. That is, the lens is manufactured by injecting a monomer solution into a mold having an empty injection space (cavity) in the shape of a lens.
As a related prior art, there is disclosed "moving distance setting device of mold for manufacturing spectacle lens" in patent document 1 (korean utility model No. 20-0236704).
The patent document 1 describes the following method: in order to accurately determine the pitch of the glass molds for manufacturing the spectacle lens, the glass molds are arranged apart from each other by using a mold chuck, in which state an adhesive tape is adhered to the outer circumferential surface of the glass mold, and then a monomer solution is manually injected into the glass mold where the encapsulating operation is completed.
However, the technique of manually injecting the monomer into the glass mold as disclosed in patent document 1 depends on the skill of the injector as a whole, and therefore, there is a problem that a defect may occur depending on the skill and the operation efficiency may be lowered. In particular, since a high level of skill is required to accurately inject the monomer in a predetermined amount at a time, there is a problem that bubbles are generated inside the mold if an unskilled person is involved.
In addition, since the liquid monomer generates volatile gas harmful to human body, it may have bad influence on the health of the operator when it is operated for a long time.
Patent document 2 (korean patent No. 10-1383132) discloses "an automatic monomer injection apparatus for an ophthalmic lens and a method for producing an ophthalmic lens using the same".
On the other hand, patent document 2 discloses that in the step of injecting the monomer solution into the cavity formed by the pair of molds, the position of the lens mold is grasped by using a displacement sensor (laser sensor) for sensing the position of the lens mold, the water level of the raw material filled into the lens mold is sensed by the second moving portion, the monomer injection amount of the injection nozzle is adjusted by the injection amount adjusting portion, and when the monomer reaches a certain water level, the amount of the injected monomer is adjusted to 5mm at 1 stage and 10mm at 2 stages.
However, as described in patent document 2, when the water level of the raw material (monomer solution) is sensed by the displacement sensor, the viscosity of the monomer solution is higher than that of water and the change in the water level is a two-dimensional, bilaterally symmetric parabolic shape rather than a horizontal change, so that there is a problem that it is difficult to accurately sense the water level in real time, and thus even if the injection amount is adjusted in each stage, it is difficult to inject an accurate amount, and an insufficient injection amount or an excessive injection amount causes product defects and contamination of injection equipment due to an excessive amount of the monomer solution, thereby possibly hindering stable operation.
Further, patent document 3 (japanese patent No. 3707189) discloses a method for automating a step of injecting a plastic raw liquid into a mold for molding in a plastic lens manufacturing process, which includes a first step of measuring a width between first and second wall portions in a cavity to set a first flow rate and a first time, and then injecting the plastic raw liquid into the cavity at the first flow rate until the first time, and a second step of injecting the plastic raw liquid into the cavity at a second flow rate smaller than the first flow rate after the first step, whereby the raw liquid is injected at a small flow rate only after the raw liquid is injected at a large flow rate for a predetermined time and immediately before the injection is completed, thereby reducing an injection time and reducing an amount of overflowing.
On the other hand, the injection method according to patent document 3 has a disadvantage that although the injection time and the amount of overflow can be reduced by reducing the injection amount and the injection time of the plastic raw liquid in stages in consideration of the space characteristics inside the cavity, the liquid level change characteristics of the plastic raw material having high viscosity are not taken into consideration when the plastic raw material for lens production is injected into the lens mold, and therefore the overflow of the plastic raw material cannot be effectively prevented or the injection amount of the plastic raw material cannot be optimally controlled.
Patent document 4 (japanese laid-open patent No. 2008-80766) discloses a method for molding a plastic lens, which comprises: in the same manner as in the case of pouring a wine with a wine glass tilted, when a liquid-phase molding material is injected into a mold, the material monomer is filled by initially injecting the material with the injection port tilted slightly to one side from the upper center so as to leave as little foam as possible, and after the injection is performed to a certain extent, rotating (tilting) the mold so that the injection port is positioned at the upper center.
On the other hand, although patent document 4 is an optimum method for injecting the raw material without leaving any foam, it is still insufficient to inject an accurate amount of the raw material.
[ Prior art documents ]
[ patent document ]
(patent document 1) Korean granted Utility model No. 20-0236704 (granted 2001.06.21)
(patent document 2) Korean patent application No. 10-1383132 (granted 2014.04.02)
(patent document 3) Japanese patent No. 3707189 (2005.08.12)
(patent document 4) Japanese laid-open patent No. 2008-80766 (publication 2008.04.10)
Disclosure of Invention
Technical problem to be solved
The present invention has been made to solve the above problems, and an object of the present invention is to provide an automatic injection method of a mold for a monomer for an optical material, which is capable of producing a high-quality lens by confirming a change in a liquid level of a monomer solution filled in a mold in real time by a visual recognition system to accurately control an injection amount, thereby always supplying a monomer having an optimal oil amount, and which is excellent in productivity and hardly causes defective products, and an automatic injection apparatus used in the method.
Technical scheme for solving problems
In order to achieve the above object, the present invention provides a method for automatically injecting a monomer solution into a cavity formed between a pair of molds having sealed outer peripheries by a monomer injector, the method comprising:
(a) shooting the liquid level change of the monomer solution injected into the die cavity by using a visual recognition system;
(b) comparing the shot liquid level change with liquid level change shapes of all stages of the monomer solution stored in advance;
(c) and if the liquid level change shape of the injected monomer solution is consistent with the previously stored monomer liquid level change shape, the controller adjusts the injection amount of the monomer injector according to each stage to inject the monomer solution to fill the cavity.
Preferably, the vision recognition system is disposed in front of the mold, and a backlight is disposed behind the mold, so that the vision recognition system disposed in front of the mold photographs a shadow of a two-dimensional shape formed by a liquid level of the monomer solution and an outline of the mold by light irradiated from the backlight.
Preferably, the previously stored monomer liquid level changing shape is provided with a region in which an injection amount is changed in each stage at a plurality of branch points of a liquid level formed when the monomer solution is injected, and the controller controls the injection amount of the monomer injector to be decreased to a set next stage when the photographed liquid level reaches the region. More preferably, the previously stored monomer solution level changing shape is provided with a region in which a plurality of branch points of the shoulder portion of the parabolic liquid level formed when the monomer solution is injected change the injection amount in each stage.
Preferably, the injector is controlled to maintain the nozzle tip in a state of entering the inside of the mold cavity while injecting the monomer solution, and to leave the outside of the mold cavity at a stage prior to the final stage.
In one embodiment of the present invention, the pair of molds are sealed with an adhesive tape and then supplied. In this case, it is preferable that a part of the tape is opened before the monomer solution is injected, and in this state, the nozzle of the monomer injector is inserted into the cavity to inject the monomer solution, and then, the cavity is sealed.
Further, the present invention provides an automatic mold injection apparatus for a single body for an optical material, which injects a monomer solution into a cavity formed between a pair of molds whose outer peripheries are sealed, by a monomer injector, comprising:
a monomer injector for injecting a monomer solution into a cavity of the mold;
the visual recognition system is used for shooting the liquid level change of the monomer solution injected into the die cavity; and
and a controller for comparing the liquid level change image photographed in the vision recognition system with liquid level change shapes of the monomer solution stored in advance at each stage, and adjusting the injection amount of the monomer injector according to each stage when the liquid level change shape of the injected monomer solution is identical to the liquid level change shape of the monomer stored in advance.
In an embodiment of the present invention, the pair of molds are sealed at their peripheries by an adhesive tape, and the automatic injection apparatus further includes: and the adhesive tape tearing device tears a part of the adhesive tape on the mould to form a monomer injection opening, and re-bonds the torn adhesive tape after injecting the monomer solution.
Preferably, the tape dispenser includes: the clamp is operated to clamp one side of the adhesive tape to be torn off and then bonded again to be in the original state; and a servo motor capable of causing the jig to perform a motion similar to a rotation motion of the wrist.
Preferably, the tape dispenser further comprises a roller for pressing the tape against the outer periphery of the mold when the tape is re-adhered.
Effects of the invention
According to the embodiment of the invention, when the viscous monomer solution is injected into the cavity in the mold, the liquid level change of the monomer solution is shot in real time, and the injection amount based on the liquid level change is adjusted in stages, so that the injection amount of the monomer solution is not excessive or insufficient and the monomer solution is accurately injected, thereby producing the lens with uniform quality, improving the injection speed of the monomer and greatly improving the efficiency of the monomer injection operation. This prevents a defect due to a shortage of the amount of the monomer solution injected, and also prevents an abnormality in the operation of the apparatus or a trouble in the apparatus due to an excessive amount of the monomer solution injected.
In addition, in the input of the die, all the encapsulation, the tearing-off of the adhesive tape and the injection of the monomer, the re-bonding operation of the adhesive tape and the discharging operation of the die injected with the monomer can be completed automatically and mechanically, so that the cost can be saved and the problem that an operator touches the medicine in the manual operation can be solved.
Drawings
Fig. 1 is a top view structural view of a lens manufacturing apparatus according to an embodiment of the present invention.
Fig. 2 is a perspective view of a lens manufacturing apparatus according to an embodiment of the present invention.
FIG. 3 is a flow chart of a lens manufacturing process according to an embodiment of the invention.
Fig. 4 is a structural view of a main part of the automatic monomer injection device shown in fig. 2 and 3.
Fig. 5 is a front view schematically showing a state where the monomer solution is injected into the cavity in fig. 4.
FIG. 6 is an enlarged schematic view of the injection state of each stage of the monomer solution in the present invention.
FIG. 7 is a graph for explaining the change in the amount of the monomer solution injected at each stage in the present invention.
Detailed Description
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
Fig. 1 and 2 schematically show the overall configuration of a lens manufacturing apparatus using the automatic monomer injection method and the automatic injection apparatus of the present invention, fig. 3 sequentially shows lens manufacturing steps of the lens manufacturing apparatus shown in fig. 1 and 2, fig. 4 shows the automatic monomer injection apparatus of the present invention, and the lens manufacturing apparatus shown in the figure includes: a tray loader 10 on which a plurality of molds are placed (refer to fig. 4 to 6); a loading picker 20 for grasping and lifting the mold from the tray loader 10; a first conveyor 30 for aligning the pair of molds supplied from the loading picker 20 and transferring the molds to a process for encapsulation; a tape bonding unit 40 for aligning the pair of molds transferred by the first conveyor 30 and bonding a tape on the outer periphery; a tape loading unit 50 for supplying a tape to the tape bonding unit 40; a second conveyor 60 and a third conveyor 70 for transferring a mold encapsulated at the outer periphery of the tape bonding unit 40 to a next process; an inverter 80 for inverting the mold transferred by the third conveyor 70; a tape dispenser 90 for separating a part of the upper tape T and re-adhering the separated tape T while standing and holding the mold turned by the inverter 80; a monomer injector 100 for injecting a monomer solution S into a cavity inside the mold M having an inlet I secured by the tape cutter 90; an unloading picker 110 for unloading the mold M into which the monomer is injected by the monomer injector 100 and sealed with the tape T by the tape cutter 90; and a disk unloader 120.
The disk loader 10, the loading picker 20, the first conveyor 30, the tape splicing unit 40, the tape loading unit 50, the second conveyor 60, the third conveyor 70, the inverter 80, the unloading picker 110, and the disk unloader 120 are constructed by a general mechanism for loading, transferring, peripheral encapsulation, inverting, and unloading of male and female molds in the field of lens manufacturing in the art, and thus, a detailed illustration and a detailed description thereof are omitted, and in the lens manufacturing apparatus shown in fig. 1 and 2, as shown in fig. 3, a lens is manufactured through steps of loading S10, encapsulation S20, an opening tape S30, monomer injection S40, sealing tape S50, and unloading S60 of a mold, and as a subsequent step, a lens is completed through a step of separating from the mold after hardening of the monomer.
However, briefly explaining the above components, the pallet loader 10 loads a plurality of male and female molds to a pallet by a vacuum suction method, supplies the pallet to a loading position, and the loading picker 20 grasps and lifts the molds loaded to the loading position and transfers the molds to the first conveyor 30, and at this time, the bar code reader recognizes a bar code given to the male and female molds, sequentially grasps and lifts one male mold and one female mold, and transfers the molds to the first conveyor 30.
The first conveyor 30 transfers the molds transferred from the loading picker 20 to the tape bonding unit 40, and the tape bonding unit 40 winds the tape around the outer circumference of the upper and lower male and female molds using a stepping motor after adjusting the position (pitch) between the molds using an electrode signal in a state where the upper and lower portions grasp the pair of male and female molds by vacuum suction, thereby forming a cavity for filling the monomer solution therein.
The tape loading unit 50 is used to supply the scotch tape to the tape splicing unit 40, to unwind the tape wound up in a roll state for supply, and to perform cutting with a cutter after the taping operation is completed.
The second and third conveyors 60 and 70 function to transfer the molds discharged from the tape bonding unit 40 to an inverter 80, and the inverter 80 is used to invert the molds with the adhesive tape bonded thereto up and down, and to make the remaining position of the adhesive tape wound around the outer circumference face up before the mold products are put on the third conveyor 70, so that interference does not occur when the chucks of the monomer injector 100 perform gripping.
In one aspect, the third conveyor 70 also functions to transfer the mold, into which the monomer solution is injected, to a position where the loading picker 110 grips and lifts up.
The unloading picker 110 transfers a mold, to which a monomer solution is injected through the monomer injector 100 and a tape is re-adhered, to a tray on the unloading tray 120 by vacuum suction, and the unloading tray 120 discharges the tray to the outside after receiving the mold at a transfer position and after loading the mold.
In the lens manufacturing apparatus shown in fig. 1 and 2, the mold loaded on the tray is supplied to the monomer injection device side by the picker and the conveyor, and after the monomer injection is completed, the mold is unloaded to the tray by the conveyor and the picker again, but the present invention is not limited thereto, and the lens manufacturing apparatus may be used in which the mold is transferred to the monomer injection device by the conveyor, and after the monomer injection, the mold is discharged again by the conveyor.
Hereinafter, a monomer automatic injection device, which is a main part of a lens manufacturing apparatus, and a method for injecting a monomer into a cavity in a mold by the automatic injection device will be described in detail.
In fig. 4, there is shown a monomer automatic injection apparatus according to a preferred embodiment of the present invention, which includes:
a tape dispenser 90 for separating a part of the tape T from a pair of molds M whose outer peripheries are sealed with the tape T to form an inlet I for injecting a monomer, and for re-attaching the separated tape T after injecting a monomer solution S into a cavity inside the mold M through the inlet I;
a monomer injector 100 for injecting a monomer solution S into a cavity of the mold M;
a vision recognition system 130 for photographing a change in the liquid level of the monomer solution S injected into the cavity of the mold M; and
and a controller (not shown) for comparing the liquid level change image photographed by the vision recognition system 130 with the liquid level change shapes of the monomer solutions stored in advance at the respective stages, and adjusting the injection amount of the monomer injector 100 at the respective stages when the liquid level change shape of the injected monomer solution matches the liquid level change shape of the monomer stored in advance.
The tape dispenser 90 includes: a clamp 92 operated by air pressure to clamp one side of the tape T to be torn off and then re-adhered to an original state; and a servo motor 94 for causing the gripper 92 to perform a similar operation to the rotation of the wrist, and the tape dispenser 90 includes, although not shown, a forward/backward movement cylinder, a Y-axis vertical cross robot, and a Z-axis vertical cross robot for performing forward/backward movement for approaching and separating the tape toward the mold M, a left/right sliding operation for separating the tape from the outer periphery of the mold and re-adhering, and an up/down lifting operation.
Holding the mold M supplied by the third conveyor 70 and keeping the chuck G in a state of being vertically erected, in the state as described above, the monomer injector 100 is raised to the upper portion to wait at the injection position in order to inject the monomer, the tape T is torn off by the tape tearing device 90 in order to secure the injection port I at the injection position, in the state where the tape T is torn off, the monomer injector 100 is lowered and the nozzle 102 is inserted into the inside of the injection port I to complete the injection of the monomer solution S, and the injection amount and the injection time of the monomer solution S are adjusted by the flow rate adjusting valve 104.
The control of the flow rate control valve 104 is performed by a controller (not shown) that performs feedback control by an image signal sensed by the visual recognition system 130, which will be described later.
Further, when the tape T is newly adhered by the tape dispenser 90, the chuck G is horizontally rotated by a rotary cylinder (not shown) and assists the tape T to be adhered in an original state, and when the tape dispenser 90 is provided with a roller (not shown) for closely adhering the tape T to the outer periphery of the die M, the roller presses the outer side of the tape T.
The vision recognition system 130 is installed in front of (in front of) the mold M that is vertically erected, and a backlight 132 is installed on the back surface of the mold M, so that the vision recognition system 130 installed in front of the mold M takes a shadow of a two-dimensional shape formed by the liquid surface of the monomer solution S injected into the mold M and the outer contour of the mold M by light irradiated from the backlight 132, and transmits an image signal to the controller.
On the other hand, the vision recognition system 130 is configured to perform a sliding motion in the left and right directions by a pneumatic cylinder or the like so as not to interfere with the tape dispenser 90, so that the vision recognition system is aligned on a line formed by the mold M and the backlight 132 when the injection motion is performed by the monomer injector 100, and is returned to a waiting position when the tape is separated and re-attached.
The controller compares the liquid level change image photographed by the vision recognition system 130 with the liquid level change shapes of the monomer solution S stored in advance at each stage, and at this time, if the liquid level change shape of the monomer solution S injected into the cavity of the mold M is identical to the liquid level change shape of the monomer stored in advance, the injection amount of the flow rate adjusting valve 104 of the monomer injector 100 is adjusted at each stage, and the monomer solution S is injected to fill the inside of the cavity.
In the present embodiment, the monomer solution S injected into the cavity of the mold M through the nozzle 102 of the monomer injector 100 is a liquid having a certain viscosity (viscosity), as shown by the dotted line and the arrow of fig. 5, completes the liquid level change of a two-dimensional form such as a parabola, instead of a horizontal line form, and fills the inside of the cavity.
That is, when the monomer solution S discharged downward from the nozzle 102 of the monomer injector 100 is filled into a space (cavity) having a circular cross section (when viewed from the front as shown in fig. 5) formed inside the mold M, since the viscosity is relatively higher than that of general water or other liquid, in a state where the liquid droplets are not broken, first, the liquid surface of the middle portion reaches a height corresponding to the end position of the nozzle 102, and the liquid surface L of the left and right side shoulders becomes low, that is, the liquid surface of the parabola (parabola), and gradually becomes high along the arrow as the monomer solution S is injected, at this time, air inside the cavity is discharged to the outside through the injection port I, and when the monomer solution S is filled into the cavity, in order to measure the liquid surface change (injection amount), it is correct to follow the parabola-shaped liquid surface L, and therefore, in order to measure the parabola-shaped liquid surface change, a plurality of fulcrums must be specified as targets at the shoulder of the liquid level L.
Therefore, in the embodiment of the present invention, the liquid surface change shape of the shoulder portion formed by the liquid surface of the monomer solution S having a parabolic shape is measured, and based on this, the injection amount is changed in stages, so that it is possible to control the injection amount of the monomer solution to supply only an accurate amount without being too small and not too large.
The symbol V in figure 5 indicates the range of images taken at the vision recognition system 130 or displayed on the display, in order to measure the liquid level change (level) of the monomer solution having the tendency as exemplified in fig. 5 and control the injection amount at each stage based on the liquid level change, as shown in fig. 6, areas P1, P2, P3, P4 and P5 are arranged in the monomer liquid level change shape stored in advance, the region is used for changing the injection amount in each stage at a plurality of fulcrums of a shoulder portion of a liquid surface formed when the monomer solution is injected, when the liquid levels L1, L2, L3, L4, L5 photographed in real time at the vision recognition system 130 reach the regions P1, P2, P3, P4, P5, the controller adjusts the injection amount of the monomer injector 100 to a set next stage, so that an accurate amount of monomer solution can be filled in the cavity of the lens mold.
Fig. 7 shows a state in which the injection amount of the monomer solution is changed based on the liquid level change shape shown in fig. 6, the injection amount when the liquid level L1 of the monomer solution actually injected reaches the first region P1 is about 90% of the total injection amount, and when the liquid level L1 of the monomer solution reaches the first region P1, the controller decreases the opening degree of the flow rate adjustment valve 104 of the monomer injector 100, decreases the injection amount for the first time, and then when the liquid level L2 of the monomer solution reaches the second region P2 again, the controller further decreases the opening degree of the flow rate adjustment valve 104 of the monomer injector 100, decreases the injection amount for the second time (the injection amount at this time is about 95%), and then when the liquid level L3 of the monomer solution reaches the third region P3 again, the controller further decreases the opening degree of the flow rate adjustment valve 104 of the monomer injector 100, decreases the injection amount for the third time (the injection amount at this time is about 98%), when the liquid level L4 of the monomer solution reaches the fourth region P4, i.e., a position in contact with the outer periphery of the fulcrum slightly lower than the uppermost end of the mold M, the flow rate adjustment valve 104 is closed (the injection amount at this time is about 99 to 100%), because the liquid level of the monomer solution S is not horizontal because the liquid level is wavy (in the same state as L4) due to the flow force at the time of injection, and therefore, when the flow stops, the liquid level coincides with the outer peripheral surface of the mold M due to surface tension.
According to the automatic monomer injection method and the automatic injection device of the present invention, most of the injected amount of the monomer is injected in a short time until a certain region, and then the injected amount of the monomer is injected in a small amount in stages, so that the monomer can be injected in an accurate amount to meet the viscosity of the monomer and the shape characteristics of the mold without being excessively reduced or excessively increased, and finally, the injection time of the monomer can be shortened.
On the one hand, the fifth region P5 is a region for sensing when the monomer solution S is excessively injected, senses that the injection amount of the monomer solution is wrong due to poor setting of the monomer injector or other external factors, and when the fifth region P5 senses the liquid level of the monomer solution, it is necessary to check and reset the apparatus, thereby transmitting a check signal.
In addition, the nozzle 102 controlled as the monomer injector 100 maintains a state in which the tip of the nozzle 102 enters the inside of the cavity while the nozzle 102 is controlled to be released to the outside of the cavity in the previous stage P3 to the final stage when the monomer solution is injected, as shown in fig. 5.
In this example, although a method of controlling the amount of monomer solution injected in stages on the assumption of a virtual mold is described, since the cross-sectional shape of the mold used for producing an ophthalmic lens is various, the volume of the cavity and the internal shape of the cavity are different, and the viscosity (viscosity) is different depending on the type of monomer, the liquid surface change shape is different when monomer is injected.
Therefore, it is necessary to measure characteristics due to the change of the liquid surface shape according to the type of the mold and the type of the monomer, and to set and store different image and sensing areas P1 to P5 in the controller, the image and sensing areas having different liquid surface change shapes according to the type of the mold and the type of the monomer.
In the figure:
10: tray loader, 20: loading pickup, 30: first conveyor, 40: tape bonding unit, 50: tape loading unit, 60: second conveyor, 70: third conveyor, 80: turner, 90: tape dispenser, 92: a jig, 94: servo motor, 100: monomer injector, 102: nozzle, 104: flow rate control valve, 110: unloading picker, 120: disc stripper, 130: visual recognition system, 132: backlight, G: chuck, I: inlet, L, L1-L5: liquid level, M: mold, P1-P5: region, S: monomer solution, T: tape, V: the image range.
Claims (15)
1. An automatic mold injection method for a single body for an optical material, which is a method for injecting a monomer solution into a cavity formed between a pair of molds having sealed outer peripheries by a monomer injector, comprising:
(a) shooting the liquid level change of the monomer solution injected into the die cavity by using a visual recognition system;
(b) comparing the shot liquid level change with liquid level change shapes of all stages of the monomer solution stored in advance; and
(c) as a result of the comparison, if the liquid level change shape of the injected monomer solution is identical to the previously stored liquid level change shape of the monomer, the controller adjusts the injection amount of the monomer injector in each stage to inject the monomer solution to fill the inside of the cavity.
2. The method of claim 1, wherein the vision recognition system is disposed in front of the mold, and a backlight is disposed behind the mold, so that the vision recognition system disposed in front of the mold photographs a shadow of a two-dimensional shape formed by a liquid level of the monomer solution and an outline of the mold by light irradiated from the backlight.
3. The method of claim 1, wherein the previously stored liquid surface variation shape of the monomer is provided with a region for changing an injection amount of the monomer solution in each step at a plurality of support points of the liquid surface formed at the time of injection of the monomer solution, and the controller adjusts the injection amount of the monomer injector to a next step when the photographed liquid surface reaches the region.
4. The automatic mold injection method of a monomer for optical material according to claim 3, wherein the previously stored monomer liquid level change shape is provided with a region in which a plurality of branch points of the shoulder portion of the parabolic liquid level formed at the time of injecting the monomer solution change the injection amount in each stage.
5. The automatic mold injection method of a single body for optical material as claimed in claim 1, wherein said injector is controlled to maintain a state in which a nozzle tip enters inside the cavity while injecting the monomer solution, and to leave outside the cavity at a stage prior to the final stage.
6. The method of claim 1, wherein the pair of molds are sealed with an adhesive tape and then supplied.
7. The automatic mold injection method of a single body for optical materials according to claim 6, wherein a nozzle of a monomer injector is inserted into a cavity of a mold to inject the monomer solution in a state where a portion of the adhesive tape is opened before the monomer solution is injected, and then the mold is sealed.
8. An automatic mold injection device for a single body for an optical material, which is a device for injecting a monomer solution into a cavity formed between a pair of molds having sealed outer peripheries by a monomer injector, comprising:
a monomer injector for injecting a monomer solution into a cavity of the mold;
the visual recognition system is used for shooting the liquid level change of the monomer solution injected into the die cavity; and
and a controller for comparing the liquid level change image photographed in the vision recognition system with liquid level change shapes of the monomer solution stored in advance at each stage, and adjusting the injection amount of the monomer injector according to each stage when the liquid level change shape of the injected monomer solution is identical to the liquid level change shape of the monomer stored in advance.
9. The automatic mold injection apparatus for a single body for optical materials according to claim 8,
further comprising a backlight disposed at a back side of the mold,
the visual recognition system is arranged in front of the mold, and takes a picture of the shadow of the two-dimensional shape formed by the liquid level of the monomer solution and the outline of the mold by the light irradiated by the backlight.
10. The automatic mold injection apparatus for monomer for optical material according to claim 8, wherein a plurality of branch points for the liquid surface formed at the time of injecting the monomer solution are provided in the monomer liquid surface changing shape stored in advance by the controller to change the injection amount in each stage, and when the photographed liquid surface reaches the region, the controller adjusts the injection amount of the monomer injector to the next stage that is set.
11. The automatic mold injection device for a monomer for optical material as set forth in claim 10, wherein the controller stores in advance a monomer liquid level change shape in which a region for changing an injection amount in each stage is provided at a plurality of support points of a shoulder portion of a parabolic liquid level formed at the time of injecting the monomer solution.
12. The automatic mold injection apparatus for a single body for optical materials according to claim 8,
the pair of molds are sealed at their outer peripheries by an adhesive tape,
further comprising: and the adhesive tape tearing device tears a part of the adhesive tape on the mould to form a monomer injection opening, and re-bonds the torn adhesive tape after injecting the monomer solution.
13. The apparatus for automatically injecting mold of a single body for optical material as set forth in claim 12, wherein said tape cutter comprises: the clamp is operated to clamp one side of the adhesive tape to be torn off and then bonded again to be in the original state; and a servo motor capable of causing the jig to perform a motion similar to a rotation motion of the wrist.
14. The apparatus for automatically injecting a mold for molding a single body of optical material as claimed in claim 12, wherein said tape cutter further comprises a roller for pressing the tape against the outer periphery of the mold when the tape is re-adhered.
15. The apparatus of claim 8, wherein the molds supplied to the monomer injector are individually supplied by a conveyor or supplied in a state that a plurality of trays are loaded.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR10-2017-0059594 | 2017-05-12 | ||
| KR20170059594 | 2017-05-12 | ||
| PCT/KR2018/004609 WO2018208030A1 (en) | 2017-05-12 | 2018-04-20 | Automatic injection method and automatic injection apparatus of monomer mold for optical material |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN110612197A CN110612197A (en) | 2019-12-24 |
| CN110612197B true CN110612197B (en) | 2021-07-02 |
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| CN201880030730.2A Active CN110612197B (en) | 2017-05-12 | 2018-04-20 | Method and apparatus for automatically injecting mold for optical material monomer |
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| Country | Link |
|---|---|
| JP (1) | JP6936874B2 (en) |
| KR (1) | KR102081498B1 (en) |
| CN (1) | CN110612197B (en) |
| WO (1) | WO2018208030A1 (en) |
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| KR102133094B1 (en) * | 2018-10-29 | 2020-07-10 | 주식회사 케이오씨솔루션 | Method for injecting monomer in mold for manufacturing optical material |
| CN113843947B (en) * | 2020-06-25 | 2023-07-28 | 株式会社大镐技术 | Lens and mold transfer system |
| KR20230141020A (en) | 2022-03-31 | 2023-10-10 | 주식회사 엠엘텍 | Process for producing plastic lens |
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Also Published As
| Publication number | Publication date |
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| WO2018208030A1 (en) | 2018-11-15 |
| JP2020523211A (en) | 2020-08-06 |
| JP6936874B2 (en) | 2021-09-22 |
| KR102081498B1 (en) | 2020-02-25 |
| CN110612197A (en) | 2019-12-24 |
| KR20180124703A (en) | 2018-11-21 |
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