IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0147614
(2005-06-08)
|
등록번호 |
US-7854865
(2011-02-14)
|
발명자
/ 주소 |
- Chiu, Hao Wen
- Mayr, Roger A.
- Yang, Hsinjin E.
|
출원인 / 주소 |
|
대리인 / 주소 |
Keusey & Associates, P.C.
|
인용정보 |
피인용 횟수 :
1 인용 특허 :
71 |
초록
▼
Methods are disclosed to injection mold resins, like polycarbonate, to form solid optical lenses. The lenses are ideally suited for use as very thin coating carriers. The method involves closing the mold with a clamp force less than the force exerted on the insert during injection. During injection
Methods are disclosed to injection mold resins, like polycarbonate, to form solid optical lenses. The lenses are ideally suited for use as very thin coating carriers. The method involves closing the mold with a clamp force less than the force exerted on the insert during injection. During injection the mold is allowed to breathe thereby overcoming many of the obstacles associated with injection molding very thin lenses. As the injection pressure subsides, the mold begins to close to perform a coining operation, resulting in a strong, high yield carrier or lens.
대표청구항
▼
What is claimed is: 1. A method for injection molding thin lenses with a coining operation, the method comprising the steps of: providing an injection molding machine with two mold halves that are opened and closed by a mold clamp along a parting line, wherein each mold half includes a sleeve secur
What is claimed is: 1. A method for injection molding thin lenses with a coining operation, the method comprising the steps of: providing an injection molding machine with two mold halves that are opened and closed by a mold clamp along a parting line, wherein each mold half includes a sleeve securely fixed to the respective mold half and a mold insert secured in a fixed position within the sleeve, wherein the insert, sleeve and respective mold half remain securely fixed in position relative to one another during the entire process; closing the mold halves with the mold clamp to a predetermined clamp force Fc that is less than a net integrated force exerted on the mold inserts during injection, whereby the closed inserts define a cavity; injecting molding material into the cavity via at least one gate so that the force exerted on the inserts by the molding material is transferred via the securely fixed position of the inserts to the mold halves to force the mold halves open along the parting line of the mold thereby reducing flow resistance and allowing the material to reach portions of the mold insert periphery; and coining a lens having a section less than 1 mm thick as the net integrated force on the inserts subsides and the mold halves close back down. 2. The method of claim 1, wherein reducing the flow resistance comprises: venting the cavity through an open parting line of the mold. 3. The method of claim 1, wherein reducing the flow resistance comprises: increasing a cavity height from the at least one gate to remote portions of the insert periphery. 4. The method of claim 1, wherein reducing the flow resistance comprises: venting the cavity in combination with increasing a cavity height. 5. The method of claim 3, wherein during the injecting step, the molding material is in intimate contact with the inserts at a thickness greater than the final coined lens thickness. 6. The method of claim 5, wherein said coining step includes reducing the thickness of the lens as the mold closes. 7. The method of claim 6, wherein the step of coining comprises coining a lens between 0.5 and 0.6 mm thick. 8. The method of claim 1, wherein the step of coining comprises coining a lens between 0.5 and 0.6 mm thick. 9. The method of claim 1, wherein following said injecting step, the method further includes the step of shifting to packing pressure mode so that molding material stops flowing into the cavity. 10. The method of claim 1, wherein said injecting step includes injecting molding material at a speed of at least about 3 ips. 11. The method of claim 1, wherein said injecting step includes injecting molding material at an injection pressure of at least about 10,000 psi. 12. The method of claim 1, wherein the coined lens is utilized in a coating transfer process to apply a coating to another lens. 13. The method of claim 1, wherein the molding material is polycarbonate. 14. The method of claim 13, wherein the polycarbonate has a viscosity of less than 400 Pa for shear rates below 1,000/s. 15. The method of claim 1, wherein the lens is made of thermoplastic having a viscosity less than 400 Pa for shear rates below 1,000/s. 16. The method of claim 15, wherein the lens comprises a plano carrier. 17. The method of claim 16, wherein following the coining step, the method further comprising the step of: depositing a coating on the plano carrier and transferring the coating to another lens. 18. The method of claim 17, wherein the plano carrier has a uniform thickness of between 0.5 mm and 0.6 mm across its entire surface. 19. The method of claim 1, wherein the lens has a negative power and a center thickness of less than about 1 mm. 20. The method of claim 15, wherein the lens has a negative power and a center thickness of less than about 1 mm. 21. The method of claim 1, wherein the lens has a positive power and an edge thickness of less than about 1 mm. 22. The method of claim 15, wherein the lens has a positive power and an edge thickness of less than about 1 mm.
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