US 2024/0227333 A9 · INJECTION MOULDING OF OPTICAL COMPONENTS

Abstract

A method for injection moulding an optical component (20), e.g. a cover for a luminaire, with an incorporated optical function, the component (20) comprising an injection moulded body (18) and at least one optically functional relief structure (4) applied thereto, the relief structure (4) forming or contributing to the optical function of the component (20) to be moulded, wherein the method comprises: (i) providing an insert (2) comprising the said optical structure (4) in the form of an open-face relief structure (4) provided on a face, surface or portion of the insert (2), (ii) mounting the insert (2) inside a mould cavity (11) in which the component (20) is to be moulded, with the open-face relief structure (4) facing and at least partially abutting a surface portion of the mould cavity (11), and (iii) rear-injection moulding a body (18) of the component (20) within the mould cavity (11) so as to incorporate the insert (2) in the component body (18), wherein the said method is carried out with parameters selected and/or controlled such that during the injection moulding step (iii) the temperature at or on the face, surface or portion of the insert (2) provided with the relief structure (4) remains below the lowest of the glass transition temperature, melting temperature and temperature of onset of thermal decomposition of the material of that face, surface or portion of the insert (2).

Claims23

Dependent claims

A method for injection moulding an optical component with an incorporated optical function, the component comprising an injection moulded body and at least one optically functional relief structure applied thereto, the relief structure forming or contributing to the optical function of the component to be moulded, wherein the method comprises:

(i) providing an insert comprising the said optical structure in the form of an open-face relief structure provided on a face, surface or portion of the insert,
(ii) mounting the insert inside a mould cavity in which the component is to be moulded, with the open-face relief structure facing and at least partially abutting a surface portion of the mould cavity, and
(iii) rear-injection moulding a body of the component within the mould cavity so as to incorporate the insert in the component body,
wherein the said method is carried out with parameters selected and/or controlled such that during the injection moulding step (iii) the temperature at or on the face, surface or portion of the insert provided with the relief structure remains below the lowest of the glass transition temperature, melting temperature and temperature of onset of thermal decomposition of the material of that face, surface or portion of the insert.

1 more element

An apparatus for injection moulding an optical component with an incorporated optical function, the component comprising an injection moulded body and at least one optically functional relief structure applied thereto, the relief structure forming or contributing to the optical function of the component to be moulded, wherein the apparatus comprises:

(i) a mould including a cavity in which the component is to be moulded;
(ii) means for mounting inside the mould cavity an insert comprising the said optical structure in the form of an open-face relief structure provided on a face, surface or portion thereof, the insert being mountable in the mould cavity with the open-face relief structure facing and at least partially abutting a surface portion of the mould cavity;
and
(iii) means for rear-injection moulding a body of the component within the mould cavity so as to incorporate the insert in the component body,
wherein the apparatus comprises means for selecting and/or controlling parameters of the injection moulding such that during the rear-injection moulding of the component body within the mould cavity the temperature at or on the face, surface or portion of the insert provided with the relief structure remains below the lowest of the glass transition temperature, melting temperature and temperature of onset of thermal decomposition of the material of that face, surface or portion of the insert.

2 more elements

Dependencies are inferred from the claim text.

Injection moulding of optical components

Life of this patent

Injection moulding of optical components

Life of this patent

Abstract

Claims23