METHOD AND APPARATUS FOR MANUFACTURING OPTICAL COMPONENT, AND OPTICAL COMPONENT

• US 20160004002A1
• Filed: 06/29/2015
• Published: 01/07/2016
• Est. Priority Date: 07/03/2014
• Status: Active Grant

• Current Assignee: Koito Manufacturing Company Limited
• Original Assignee: Koito Manufacturing Company Limited
• Inventors: Yoshida, Kenji, Osawa, Takahito, Katayama, Masashi
• Granted Patent: US 10,195,773 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 2045/4063 preventing damage to articles caused by the ejector
• CPC Class Codes: B29C 45/37 Mould cavity walls , i.e. the inner surface forming the mould cavity, e.g. linings
• CPC Class Codes: B29C 45/401 Ejector pin constructions or mountings
• CPC Class Codes: B29D 11/0048 Moulds for lenses moulds for plastic articles in general B29C33/00
• CPC Class Codes: B29D 11/00663 Production of light guides
• CPC Class Codes: B29L 2011/00 Optical elements, e.g. lenses, prisms
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/19 Attachment of light sources or lamp holders
• CPC Class Codes: F21S 43/235 Light guides
• CPC Class Codes: F21S 43/249 with two or more light sources being coupled into the light guide
• CPC Class Codes: F21S 43/315 using total internal reflection

Abstract

A method for manufacturing an optical component having an optical surface includes: injecting a molten resin into a cavity; curing the molten resin to form the optical component; and taking the optical component out from the movable mold by moving the movable mold away from the fixed mold, and piercing a part of the optical surface (first incident surface) of the optical component attached to the movable mold by the protruding pin, and then wherein a tip end face of the protruding pin includes: a first surface; and a second surface having an area smaller than an area of the first surface, and extending continuously from the first surface in a curved form, the second surface being located on at least a part of an outer circumferential edge portion of the tip end face, that is, a tip end in the first direction.

Claims

1. A method for manufacturing an optical component having an optical surface, the method comprising:

defining a cavity by making a fixed mold and a movable mold come into contact with each other, the movable mold having a protruding pin that reciprocates in a first direction and configured to reciprocate in the first direction;

injecting a molten resin into the cavity;

curing the molten resin in the cavity to form the optical component; and

taking the optical component out from the movable mold by moving the movable mold away from the fixed mold in the first direction, and piercing a part of the optical surface of the optical component attached to the movable mold by the protruding pin,

wherein a tip end face of the protruding pin comprises;

a first surface; and

a second surface having an area smaller than an area of the first surface and extending continuously from the first surface in a curved form, the second surface being located on at least a part of an outer circumferential edge portion of the tip end face, that is, a tip end in the first direction,

wherein an angle of the second surface relative to the first direction is larger than an angle of a portion of the first surface adjacent to the second surface relative to the first direction.

2. The method of claim 1, wherein the angle of the second surface relative to the first direction is 60 degrees or more.

3. The method of claim 1, wherein the first surface is a concave curved surface, and the second surface is provided on at least a part of a peripheral edge of the first surface.

4. The method of claim 2, wherein the first surface is a concave curved surface, and the second surface is provided on at least a part of a peripheral edge of the first surface.

6. An optical component manufactured by the method of claim 1, the optical component comprising:

an optical surface; and

a step portion provided on at least a part of a peripheral edge portion of the optical surface, the step portion coming into contact with the tip end face of the protruding pin.

7. An optical component manufactured by the method of claim 2, the optical component comprising:

an optical surface; and

a step portion provided on at least a part of a peripheral edge portion of the optical surface, the step portion coming into contact with the tip end face of the protruding pin.

8. An optical component manufactured by the method of claim 3, the optical component comprising:

an optical surface; and

a step portion provided on at least a part of a peripheral edge portion of the optical surface, the step portion coming into contact with the tip end face of the protruding pin.

9. An optical component manufactured by the method of claim 4, the optical component comprising:

an optical surface; and

a step portion provided on at least a part of a peripheral edge portion of the optical surface, the step portion coming into contact with the tip end face of the protruding pin.

5. An apparatus for manufacturing an optical component, comprising:

a fixed mold; and

a movable mold defining a cavity in conjunction with the fixed mold, and reciprocating in a first direction, the movable mold having a protruding pin that reciprocates in the first direction,

wherein a tip end face of the protruding pin comprises;

a first surface; and

a second surface having an area smaller than an area of the first surface, and extending continuously from the first surface in a curved form, the second surface being located on at least a part of an outer circumferential edge portion of the tip end face, that is, a tip end in the first direction,

wherein an angle of the second surface relative to the first direction is larger than an angle of a portion of the first surface adjacent to the second surface relative to the first direction.