# US 9,039,905 B2 · Method of forming a lighting system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,039,905 B2 - Document ID: US9039905B2 - Status: Granted - Kind: B2 - Application number: 13/769,459 - Filed: 2013-02-18 - Published: 2013-08-22 - Granted: 2015-05-26 - Earliest claimed: 2012-02-17 - Assignees: 3M Innovative Properties Company - Applicants: 3M Innovative Properties Company - Inventors: Andrew J. Ouderkirk; Erin A. Binder; Nicholas T. Gabriel; Kelly Reed Ingham; Wesley A. Raider; Shrey Gupta; Olester Benson, Jr.; Huang Chin Hung - Web page: https://patentgrep.com/patent/US9039905B2 ## CPC - B29D 11/00721: {involving preforms for the manufacture of light guides} - G02B 6/0028: {Light guide, e.g. taper} - G02B 6/0031: {Reflecting element, sheet or layer} - G02B 6/0036: {2-D arrangement of prisms, protrusions, indentations or roughened surfaces} - G02B 6/0065: {Manufacturing aspects; Material aspects} - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS ## Abstract A method of forming a lighting system comprises providing a cavity having at least a first array of first optical elements and a second array of second optical elements that have a different shape than the first array, filling the cavity with a curable resin, applying a secondary optical element to the curable resin in alignment with the first optical array, curing the resin to form a cured assembly, and removing the cured assembly from the cavity. ## Claims ### Claim 1 A method of forming a lighting system, comprising: providing a cavity having at least a first array of first optical elements and a second array of second optical elements that have a different shape than the first array; filling the cavity with a curable resin; applying a secondary optical element to the curable resin in alignment with the first optical array; curing the resin to form a cured assembly; and removing the cured assembly from the cavity. ### Claim 2 (depends on 1) The method of claim 1, further comprising applying a molding tool to a same side of the first array as is the secondary optical element. ### Claim 3 (depends on 1) The method of claim 1, wherein the method is a continuous process. ### Claim 4 (depends on 1) The method of claim 1, wherein the method is a batch process. ### Claim 5 (depends on 1) The method of claim 1, wherein the cavity comprises a depressed area formed in a mold having a molding surface. ### Claim 6 (depends on 5) The method of claim 5, further comprising applying a release agent to the molding surface. ### Claim 7 (depends on 6) The method of claim 6, wherein the release agent comprises at least one of a diamond like coating, silicone, acrylate, fluoropolymer, and a vapor deposited material. ### Claim 8 (depends on 1) The method according to claim 1, wherein the curable resin is applied by at least one of dip coating, wire bar coating, doctor blade coating, ink jet coating, roll coating, and silk screen coating. ### Claim 9 (depends on 1) The method according to claim 1, wherein the curable resin comprises at least one of acrylates, silicones, epoxies, esters, and vinyl compounds. ### Claim 10 (depends on 1) The method according to claim 1, wherein the first array of first optical elements comprises an array of diverter elements. ### Claim 11 (depends on 1) The method according to claim 1, wherein the second array of second optical elements comprises a backlight light guide having an array of extractors. ### Claim 12 (depends on 1) The method according to claim 1, wherein the second array of second optical elements comprises an optical coupling element. ### Claim 13 (depends on 1) The method according to claim 1, wherein the secondary optical element comprises an anamorphic light guide. ### Claim 14 (depends on 1) The method according to claim 1, wherein the curing comprises at least one of thermal curing using a thermal initiator or catalyst, thermally driven condensation, radiation curing using a photoinitiator, actinic radiation curing, and electron beam curing. ### Claim 15 (depends on 1) The method according to claim 1, wherein, after curing, applying an optically clear adhesive film to a top surface of the cured structure. ### Claim 16 (depends on 1) The method according to claim 1, wherein, after curing, vapor coating the cured structure with at least one of a dielectric material and a metal. ### Claim 17 (depends on 1) The method according to claim 1, further comprising bonding the lighting system to a display. ### Claim 18 A method of forming an extractor optical element having extraction features, comprising: providing a substrate material having an upper surface having an array of grooves formed thereon; filling the grooves with a polymer; defining the polymer using a patterned radiation and etching process; electroforming the substrate material to form a replica of the patterned upper surface with selected portions of the grooves, where the sides of the grooves can have an angle of at least 45 degrees to the plane of the upper surface; and removing the substrate from the electroform. ### Claim 19 (depends on 18) The method of claim 18, wherein the density of extraction features comprises about 10% or less of the area of a major surface of the electroform. ### Claim 20 (depends on 18) The method of claim 18, further comprising planarizing the polymer.