Method for fabricating a plastic optic element injection mold
First Claim
1. A method for fabricating an injection mold for a plastic optical component comprising the steps of:
- (a) forming at least two metal models of the plastic optic component to be produced;
(b) forming a metal shell on each of said metal models;
(c) scribing an axial line on each of said metal shells;
(d) cutting a first of said shells along a line below its axial line and the other of said shells along a line above its axial line;
(e) discarding the portion of the metal shell and the portion of the metal model from the cutting line away from the axial line for each of said shells;
(f) removing the metal model from the remaining of the metal shell and trimming the portion of the metal shell between its cutting line and the axial line for each of said shells; and
(g) combining the resulting two metal shell portions to form the injection mold.
1 Assignment
0 Petitions
Accused Products
Abstract
In order to produce precision optic elements using injection molded plastic, a metal mold is fabricated from two positive masters comprising exact metallic reproductions of the desired plastic part and on which a metal shell has been electroformed or otherwise plated. Two positive masters are required for each mold, one being formed to define the upper part of the mold and the other the lower part of the mold. Each positive master is scribed with an axial line and with a cutting line slightly offset from the axial line, the cutting line for the upper part of the mold being below the axial line and the cutting line for the lower part of the mold being above the axial cutting line. The positive masters are then cut along their cutting lines, the metal shells removed, and the portion of the remaining metal shells between their axial lines and their cutting lines is then trimmed. The upper and lower parts of the mold are then combined to define the complete injection mold.
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Citations
13 Claims
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1. A method for fabricating an injection mold for a plastic optical component comprising the steps of:
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(a) forming at least two metal models of the plastic optic component to be produced;
(b) forming a metal shell on each of said metal models;
(c) scribing an axial line on each of said metal shells;
(d) cutting a first of said shells along a line below its axial line and the other of said shells along a line above its axial line;
(e) discarding the portion of the metal shell and the portion of the metal model from the cutting line away from the axial line for each of said shells;
(f) removing the metal model from the remaining of the metal shell and trimming the portion of the metal shell between its cutting line and the axial line for each of said shells; and
(g) combining the resulting two metal shell portions to form the injection mold. - View Dependent Claims (2, 9)
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3. A method for fabricating an injection mold suitable for forming a plastic optical component comprising the steps of:
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fabricating a plurality of duplicate positive masters of the optical component from a first metal;
polishing each of said plurality of duplicate positive masters to an optical surface finish;
placing each of said duplicate positive masters in an electroforming bath;
electroforming a shell of a second metal on each of said duplicate positive masters to a predetermined thickness;
scribing an axial mold line on each of said electroformed shells;
cutting each of a set of positive masters along predetermined cutting lines to form a set of negative master segments, wherein each of negative master segments comprises a portion of the electroformed shell about a positive master;
trimming each of said negative master segments by removing an overlap region comprising a portion of the electroformed shell interposed between one of said predetermined cutting lines and said mold parting line;
separating each of said positive master segments from each of said negative master segments to form a set of negative master mold segments; and
building up a mold from a set of negative master mold segments, wherein said set of negative master mold segments completely defines the plastic optical component. - View Dependent Claims (4, 5, 6, 7, 8)
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10. A method for fabricating an injection mold for a plastic optical component comprising the steps of:
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forming two exact metal models of the plastic optic component to be produced by the mold;
forming a metal shell on each of said metal models;
defining a line through each of said shells, which lines delineate upper and lower portions of said shells, said upper portions being equal and said lower portions being equal;
cutting one of said shells along a cut line above its delineating line and the other of said shells along a cut line below its delineating line;
removing the portion of said one shell below its cut line and the portion of said other shell above its cut line;
removing the part of the metal mold above its cut line from said one shell and the part of the metal mold below its cut line from said other shell;
trimming away the segments of each shell between its delineating line and its cut line; and
combining the remaining portions of said one and said other shell to form the injection mold. - View Dependent Claims (11, 12, 13)
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Specification