Thin light managing system for directing and distributing light from one or more light sources and method for making optics structures for use in the system
First Claim
1. A method of injection molding a hybrid optics panel in a mold assembly to form first and second redirecting light pipe sections, a flat illumination surface, and a contoured lensing section on the panel, said method including the steps of:
- forming a mold cavity defined by a fixed mold portion, a facet forming portion, an edge facet forming portion, an inner moveable portion, an outer moveable portion, and a top portion;
injecting a molten material into the mold cavity;
moving the inner moveable portion against the molten material to form the contoured lensing section on the panel;
moving the outer moveable portion against the molten material independent of said movement of the inner moveable portion to form the flat illumination surface on the panel; and
applying a predetermined amount of pressure to the mold cavity to urge the molten material against the edge facet forming portion to form at least one facet on the first redirecting light pipe section of the panel and against the facet forming portion to form at least one facet on the second redirecting light pipe section of the panel opposite the flat illumination surface.
1 Assignment
0 Petitions
Accused Products
Abstract
A rear signal lamp of an automotive vehicle comprising a lamp housing and a curved cover lens for enclosing a thin light managing system. The thin light managing systems includes a plurality of backlight light-emitting diodes mounted in a light mounting substrate and secured to the lamp housing. A control module operatively connected to the light-emitting diodes for controlling the operation and illumination of the light-emitting diodes. A reflector matrix having a plurality of reflector cones corresponding to each of the light-emitting diodes in the mounting substrate and a hybrid optics panel having a direct lensing section covering the reflector matrix and light-emitting diodes and a double redirecting light pipe section surrounding the lensing section. A single light-emitting diodes is coupled along spaced apart quadrants of the redirecting light pipe. Each single light-emitting diodes emits light to the respective quadrant of the optics panel which is reflected and redirected from one or more lens facets to illuminated the front surface of the panel. The direct lensing section and redirecting light pipe illuminate distinct area on the curved cover lens.
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Citations
12 Claims
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1. A method of injection molding a hybrid optics panel in a mold assembly to form first and second redirecting light pipe sections, a flat illumination surface, and a contoured lensing section on the panel, said method including the steps of:
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forming a mold cavity defined by a fixed mold portion, a facet forming portion, an edge facet forming portion, an inner moveable portion, an outer moveable portion, and a top portion;
injecting a molten material into the mold cavity;
moving the inner moveable portion against the molten material to form the contoured lensing section on the panel;
moving the outer moveable portion against the molten material independent of said movement of the inner moveable portion to form the flat illumination surface on the panel; and
applying a predetermined amount of pressure to the mold cavity to urge the molten material against the edge facet forming portion to form at least one facet on the first redirecting light pipe section of the panel and against the facet forming portion to form at least one facet on the second redirecting light pipe section of the panel opposite the flat illumination surface. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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Specification