Lens mold and method for manufacturing lenses utilizing the lens mold

Patent metadata

Field	Value
Publication number	US-9505185-B2
Application number	US-201313965198-A
Country	US
Kind code	B2
Filing date	Aug 13, 2013
Priority date	Mar 1, 2013
Publication date	Nov 29, 2016
Grant date	Nov 29, 2016

Abstract

A lens mold includes a bottom mold and a top mold joining with the bottom mold. The bottom mold defines a first through hole. The top mold defines a second through hole. The lens mold further includes a bottom mold core and a top mold core. The bottom mold core is detachably received in the first through hole of the bottom mold. The top mold core is detachably received in the second through hole of the top mold. A plurality of microstructures is formed on a top surface of the bottom mold core near the top mold core to form a plurality of microstructures on a bottom surface of a lens formed by the lens mold. A method for manufacturing the lens with the lens mold is also provided. The lens is used as a secondary optical element for an LED.

First claim

What is claimed is:

1. A lens mold for manufacturing a lens for use as a secondary optical element for an LED (light emitting diode), comprising:
a bottom mold defining a first through hole;
a top mold matching with the bottom mold, the top mold defining a second through hole;
a bottom mold core detachably received in the first through hole of the bottom mold;
a top mold core detachably received in the second through hole of the top mold;
wherein a plurality of microstructures is formed on a top surface of the bottom mold core near the top mold core, the microstructures being configured for forming a plurality of microstructures on a bottom surface of the lens formed by the lens mold;
wherein the bottom mold core is spaced from the top mold core, the bottom mold core comprising a frosting mold core, the microstructures being formed on a top surface of the frosting mold core; and
wherein the bottom mold core further comprises an optical mold core, a positioning hole being defined at a center of the frosting mold core, the optical mold core being detachably arranged in the positioning hole, a part of the optical mold core near the top mold core being extended upwardly beyond the top surface of the frosting mold core.

2. The lens mold of claim 1 , wherein the part of the optical mold core extending above and exposed out of the top surface of the frosting mold core is hemisphere-shaped.

3. The lens mold of claim 2 , wherein the first through hole and the second through hole are communicated with each other, and a size of the first through hole is equal to that of the second through hole.

4. The lens mold of claim 3 , wherein a top end face of the optical mold core near the top mold core extends upwardly beyond a top surface of the bottom mold, a top surface of the frosting mold core is below the top surface of the bottom mold to define a space between the top surface of the frosting mold core and the top surface of the bottom mold.

5. The lens mold of claim 4 , wherein a bottom surface of the optical mold core, a bottom surface of the frosting mold core and a bottom surface of the bottom mold are coplanar, and a top surface of the top mold core and a top surface of the top mold are coplanar.

6. The lens mold of claim 3 , wherein a bottom surface of the top mold core is concave, a bottom periphery of the top mold core and the bottom surface of the top mold being coplanar, the bottom mold core, the top mold core and the bottom mold being engaged together to form a cavity for forming the lens.

7. The lens mold of claim 3 , wherein the bottom mold and the top mold are integrally formed.

8. A manufacturing method for manufacturing a lens for use as a secondary optical element for an LED, comprising steps:
providing a lens mold, the lens mold comprising a bottom mold having a first through hole, a top mold having a second through hole, a bottom mold core having a plurality of microstructures on a top surface thereof, a top mold core detachably received in the second through hole of the top mold;
arranging the bottom mold core and the top mold core respectively detachably received in the first through hole and the second through hole, and forcing the bottom mold abutting against the top mold, thereby making the top mold core, the bottom mold core and the bottom mold cooperatively defining a cavity thereamong;
injecting transparent resin material into the cavity and solidifying the transparent resin material in the cavity to form the lens; and
removing the lens from the lens mold;
wherein the bottom mold core is spaced from the top mold core, the bottom mold core comprising a frosting mold core, the microstructures being formed on a top surface of the frosting mold core; and
wherein the bottom mold core further comprises an optical mold core, a positioning hole being defined at a center of the frosting mold core, the optical mold core being detachably arranged in the positioning hole, a part of the optical mold core near the top mold core being extended upwardly beyond the top surface of the frosting mold core.

9. The manufacturing method for manufacturing the lens of claim 8 , wherein the part of the optical mold core exposed out of the top surface of the frosting mold core is hemisphere-shaped.

10. The manufacturing method for manufacturing the lens of claim 9 , wherein a size of the first through hole is equal to that of the second through hole.

11. The manufacturing method for manufacturing the lens of claim 10 , wherein a top end face of the optical mold core near the top mold core extends upwardly beyond a top surface of the bottom mold, and a top surface of the frosting mold core is below the top surface of the bottom mold to define a space defined between the top surface of the frosting mold core and the top surface of the bottom mold.

12. The manufacturing method for manufacturing the lens of claim 11 , wherein a bottom surface of the optical mold core, a bottom surface of the frosting mold core and a bottom surface of the bottom mold are coplanar, and a top surface of the top mold core and a top surface of the top mold are coplanar.

13. The manufacturing method for manufacturing the lens of claim 10 , wherein a bottom surface of the top mold core is concave, a bottom periphery of the top mold core and the bottom surface of the top mold are coplanar, the bottom mold core, the top mold core and the bottom mold being engaged together to form the cavity for forming the lens.

14. The manufacturing method for manufacturing the lens of claim 10 , wherein the bottom mold and the top mold are integrally formed.

Assignees

• Hon Hai Prec Ind Co Ltd

Inventors

• Tseng Yung-Chang

Classifications

• B29D11/00326 Primary

  having particular surface properties, e.g. a micropattern · CPC title

• B29C45/372

  provided with means for marking or patterning, e.g. numbering articles · CPC title