Method for producing high quality optical parts by casting
First Claim
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1. A method of producing a solid optical system having a protruding optical element, the element providing optical power, comprising:
- providing a mold assembly having a mold cavity, the mold assembly including a recess in one surface shaped to receive the protruding optical element;
introducing an optical material into the mold cavity, at least a portion of the optical material comprising an optical polymerizable casting compound and a further portion of the optical material disposed within the recess to form the protruding optical element; and
curing the polymerizable casting compound to provide an optical component; and
removing the optical component from the mold assembly.
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Abstract
A casting method, rather than injection molding, to produce polymer optical components and systems is provided. The casting process controls shrinkage and stress, thus providing both high bulk uniformity and high quality, accurate surfaces, by incorporating polymer films into the mold. The films may remain incorporated into the part or may optionally be removed from the part after removal from the mold. In addition, the incorporation of separately produced components within the cast part is also provided, eliminating post-casting assembly manufacturing steps.
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Citations
64 Claims
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1. A method of producing a solid optical system having a protruding optical element, the element providing optical power, comprising:
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providing a mold assembly having a mold cavity, the mold assembly including a recess in one surface shaped to receive the protruding optical element;
introducing an optical material into the mold cavity, at least a portion of the optical material comprising an optical polymerizable casting compound and a further portion of the optical material disposed within the recess to form the protruding optical element; and
curing the polymerizable casting compound to provide an optical component; and
removing the optical component from the mold assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64)
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Specification