Method for producing optical device

Patent metadata

Field	Value
Publication number	US-9561609-B2
Application number	US-201414261667-A
Country	US
Kind code	B2
Filing date	Apr 25, 2014
Priority date	Oct 14, 2013
Publication date	Feb 7, 2017
Grant date	Feb 7, 2017

Abstract

A method for producing an optical device includes steps of: providing a first mold set, a second mold set, and an inner mold member cooperating with the first mold set to define a first molding cavity; filling a first plastic material into the first molding cavity so as to form a first molded object including a first molded element; placing the first molded object and the inner mold member into the second mold set to cooperatively define a second molding cavity; filling a second plastic material into the second molding cavity so as to form a second molded object including a second molded element; and disconnecting the first and second molded elements from the first and second molded objects.

First claim

What is claimed is:

1. A method for producing an optical device, comprising the following steps of:
(a) providing a first mold set, a second mold set, and an inner mold member that is disposed in the first mold set and that cooperates with the first mold set to define a first molding cavity and a first gate spatially communicating with the first molding cavity;
(b) filling a first plastic material into the first molding cavity via the first gate so as to form a first molded object including a first molded element;
(c) placing the first molded object together with the inner mold member into the second mold set, such that the inner mold member, the first molded object, and the second mold set cooperatively define a second molding cavity and a second gate spatially communicating with the second molding cavity;
(d) filling a second plastic material into the second molding cavity via the second gate so as to form a second molded object including a second molded element which is coupled to the first molded element; and
(e) disconnecting the first molded element from the first molded object and disconnecting the second molded element from the second molded object so as to form the optical device.

2. The method according to claim 1 , wherein:
in step (a), the first and second mold sets are respectively formed with first and second down sprues, the first mold set further cooperating with the inner mold member to define a first sprue channel that spatially interconnects the first down sprue and the first gate;
in step (b), the first plastic material is filled into the first molding cavity via the first down sprue, the first sprue channel, and the first gate, and the first molded object further includes a main stem piece that is formed in the first down sprue, and a branch stem piece that is connected to the main stem piece and that is formed in the first spure channel;
in step (c), the second mold set, the inner mold member, and the branch stem piece of the first molded object cooperate to define a second sprue channel that spatially interconnects the second down sprue and the second gate, the main stem piece of the first molded object being disposed in the second down sprue; and
in step (d), the second plastic material is filled into the second molding cavity via the second down sprue, the second sprue channel, and the second gate, and the second molded object further includes a main stein piece formed in the second down sprue, and a branch stem piece that is connected to the main stem piece of the second molded object and that is formed in the second sprue channel.

3. The method according to claim 1 , wherein:
in step (a), the first mold set includes a first core, the inner mold member including a hole receiving the first core of the first mold set;
in step (c), the second mold set includes a second core having a molding surface provided with a pattern, the hole of the inner mold member receiving the second core of the second mold set; and
in step (d), the second molded object is light-transmissive, and a surface of the second molded element that abuts against the molding surface of the second core has a refractive power and is formed with a pattern that corresponds to the pattern of the second core.

4. The method according to claim 1 , wherein:
in step (b), the first molded object includes a plurality of the first molded elements; and
in step (d), the second molded object includes a plurality of the second molded elements that correspond in position respectively to the first molded elements and that are coupled respectively to the first molded elements of the first molded object to fonn a plurality of the optical devices.

5. The method according to claim 4 , wherein:
in step (a), the first mold set includes a plurality of first cores, the inner mold member including a plurality of holes receiving respectively the first cores of the first mold set;
in step (c), the second mold set includes a plurality of second cores each of which has a molding surface provided with a pattern, the holes of the inner mold member receiving respectively the second cores of the second mold set; and
in step (d), the second molded object is light-transmissive, and a surface of each of the second molded elements that abuts against the molding surface of a respective one of the second cores has a refractive power and is formed with a pattern that corresponds to the pattern of the respective one of the second cores.

6. The method according to claim 1 , wherein, in step (e), the first and second molded elements are disconnected simultaneously and respectively from the first and second molded objects.

7. A method for producing an optical device, the method comprising the steps of:
(a) providing a first mold set, a second mold set, a third mold set, and an inner mold member that is disposed in the first mold set and that cooperates with the first mold set to define a first molding cavity and a first gate spatially communicating with the first molding cavity;
(b) filling a first plastic material into the first molding cavity via the first gate so as to form a first molded object including a first molded element;
(c) placing the first molded object together with the inner mold member into the second mold set, such that the inner mold member, the first molded object, and the second mold set cooperate to define a second molding cavity and a second gate spatially communicating with the second molding cavity;
(d) filling a second plastic material into the second molding cavity via the second gate so as to form a second molded object including a second molded element which is coupled to the first molded element;
(e) placing the inner mold member together with the first molded object and the second molded object into the third mold set, such that the inner mold member, the first and second molded objects, and the third mold set cooperate to define a third molding cavity and a third gate that is in spatial communication with the third molding cavity;
(f) filling a third plastic material into the third molding cavity via the third gate, so as to form a third molded object including a third molded element which is coupled to at least one of the first and second molded elements; and
(g) disconnecting the first molded element from the first molded object, disconnecting the second molded element from the second molded object, and disconnecting the third molded element from the third molded object so as to form the optical device.

8. The method according to claim 7 , wherein:
in step (a), the first, second and third mold sets are respectively formed with first, second and third down sprues, and the inner mold member and the first mold set further cooperatively define a first sprue channel that spatially interconnects the first down sprue and the first gate;
in step (b), the first plastic material is filled into the first molding cavity via the first down sprue, the first sprue channel, and the first gate so as to form the first molded object, the first molded object further including a main stem piece formed in the first down sprue, and a branch stem piece connected to the main stem piece and formed in the first sprue channel;
in step (c), the second mold set, the inner mold member and the branch stem piece of the first molded object further define cooperatively a second sprue channel that spatially interconnects the second down sprue and the second gate, the main stem piece of the first molded object being disposed in the second down sprue of the second mold set;
in step (d), the second plastic material is filled into the second molding cavity via the second down sprue, the second sprue channel, and the second gate so as to form the second molded object, the second molded object fu

Assignees

• Genius Electronic Optical Co Ltd

Inventors

• Hou Hsien-Chang

Classifications

• B29C45/162 Primary

  using means, e.g. mould parts, for transferring an injected part between moulding stations · CPC title

• B29L2011/00

  Optical elements, e.g. lenses, prisms · CPC title

• B29C45/0062 Primary

  Joined by injection moulding · CPC title

• B29C45/14336

  Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence) · CPC title

• B29C45/14508

  Joining juxtaposed sheet-like articles, e.g. for making trim panels · CPC title