FILM INSERT MOLDING (FIM) ON A 3D SHAPE

• US 20090261490A1
• Filed: 04/22/2008
• Published: 10/22/2009
• Est. Priority Date: 04/22/2008
• Status: Active Grant

• Current Assignee: Current Lighting Solutions, LLC (f/k/a GE Lighting Solutions, LLC) (American Industrial Partners)
• Original Assignee: GE Lighting Solutions LLC (Savant Systems, LLC)
• Inventors: Martineau, Patrick, Dubuc, Eden, Bohler, Christopher L.
• Granted Patent: US 8,597,009 B2
• Time in Patent Office: Days
• US Class Current: 264/1.340
• CPC Class Codes: B29D 11/0073 Optical laminates

Abstract

Systems and methods are described for performing film insert molding (FIM) on a 3D shape, such as a traffic light shell or cover. A film is pre-generated for a surface to be covered by the film, and is inserted into a mold. A viscous material is then injected into the mold and the film bonds to the shell as the viscous material cools and hardens. The film includes a material selected to provide one or more of scratch resistance, improved shell hardness, UV protection, corrosion protection etc., and/or may be selected to alter optical characteristics of the shell.

Claims

1. A film insert molding (FIM) system, comprising

a film insert for protecting an article;

and

a mold having the shape of the article to be protected, with a ratio of radius of curvature to diameter that is within a predefined range of ratios to prevent wrinkling of the film insert, into which the film is placed; and

an injection molding component that injects viscous material into the mold to form the article, to which the film adheres as the viscous material cools.

2. The system according to claim 1, wherein the film is a scratch resistant film.

3. The system according to claim 1, wherein the film is a UV resistant film.

4. The system according to claim 1, wherein the film is a corrosion resistant film.

5. The system according to claim 1, wherein the film is a reflective film.

6. The system according to claim 1, wherein the film is a heat resistant film.

7. The system according to claim 1, wherein the film has a curvature that complements a sphere-like portion of the article to which the film is coupled.

8. The system according to claim 1, wherein the film is an opaque film having a pattern cut therein.

9. The system according to claim 8 wherein the pattern is arrow-shaped.

10. The system according to claim 9, wherein the article is a traffic light cover shell.

11. The system according to claim 1, wherein the article is a translucent cover shell for a traffic light.

12. The system according to claim 11, wherein the film increases hardness of the cover shell.

13. The system according to claim 11, wherein the film increases UV resistance of the cover shell.

14. The system according to claim 1, wherein the film acts as an optical lens when coupled to the article.

15. The system according to claim 1, wherein the film acts as an optical diffuser when coupled to the article.

16. The system according to claim 1, wherein the mold has a parabolic 3D shape with a radius of curvature to diameter ratio of approximately 1.5:

1 to approximately 10;

1.

17. A method of film insert molding of an article, comprising:

generating a film insert;

inserting the film insert into a mold; and

injecting a viscous material into the mold;

wherein the film couples to the material as the material cools and hardens; and

wherein a ratio of a radius of curvature to diameter of a surface of the mold into which the film insert is placed is between approximately 1.5;

1 and 10;

1 to prevent the film insert from wrinkling.

18. The method of claim 17, wherein the article is a translucent cover for a light, and wherein the film increases at least one of hardness and UV resistance of an exterior surface of the cover.

19. The method of claim 17, wherein the film is a parabolic in shape and congruent to an exterior surface of the article.

20. A film insert molding (FIM) system, comprising

a flexible planar film having a shape that is congruent to a surface of an translucent traffic light shell;

and

a mold having the shape of the traffic light shell, into which the film is placed and viscous material is injected to form the traffic light shell, to which the film adheres as the viscous material cools;

wherein the surface of the mold has a ratio of a radius of curvature to diameter of an interior surface of the mold is within a predefined range of ratios to prevent wrinkling of the insert film;

wherein the film provides protection from ultraviolet light and increases shell surface hardness.