DE102014202017A1 - Injection molding an optical component comprises a two-step injection molding process where the mold gate is positioned in alignment with the two lateral surfaces of the baffles to allow molten optical material flow - Google Patents

Abstract

Injection molding an optical component comprises injecting a first amount of a molten optical material through a first mold gate into the first mold cavity; and injecting a second amount of the optical material in the second mold cavity through a second mold gate where the mold gate is positioned in alignment with the two lateral surfaces of the elongated baffles to allow the flow of the molten optical material. Injection molding an optical component comprises providing a first mold cavity formed between a first mold cap and a mold core, the first mold cap having a cap injection surface, the mold core having a core injection surface and at least two spaced apart undercuts, each of the undercut having two lateral walls a depth, a width and a length; injecting a first amount of a molten optical material through a first mold gate into the first mold cavity, where the mold gate is located opposite to the undercuts in such a manner that the molding material flows into the first mold cavity in a direction parallel to the lateral walls of the undercuts and along the length of the undercuts; cooling the optical material in the first mold cavity, where the optical material makes cooling contact with the undercut walls so that at the end of the cooling time a first section of the optical component is formed , the first section including at least two elongated baffles formed by the molded material located in the undercuts, where each elongated baffle includes a front surface, an opposed back surface and two lateral surfaces; providing a second mold cavity formed between the first section of the optical component and a second mold cap; and injecting a second amount of the optical material in the second mold cavity through a second mold gate where the mold gate is positioned in alignment with the two lateral surfaces of the elongated baffles to allow the flow of the molten optical material. An independent claim is an optical lens made by injection molding in a mold through the injection of a single molten material in two injection shots of using a two step process, the optical lens comprising a first surface having a first periphery and a second surface having a second periphery; a lens body defined between the first surface and the second surface for a light beam to enter the lens through the first surface and exit the lens through the second surface where the first surface is injection molded in the first injection shot and the second surface in a second injection shot; a first mold gate mark located at the first periphery and a second mold gate mark located at the second periphery; and a first melt flow pattern including at least two spaced apart and continuous streams that fully extend within the first periphery injected through the first gate in the first shot and a second flow pattern including at least two spaced apart and continuous streams that fully extend within the second periphery injected through the second gate in the second shot, the first and second flow patterns being visible using optical testing devices.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of pending U.S. Patent Application Serial No. 13 / 172,093, filed June 29, 2011, which is a continuation of PCT Application No. WO / A. PCT / CA2011 / 000129 , filed on Feb. 1, 2011, and now no longer pending, the PCT application having the benefit of US Pat. No. US-A-5,911,331 filed on Feb. 1, 2010, the disclosure of which is incorporated herein by reference now no longer pending claimed. The disclosures of these earlier applications are hereby incorporated into the present subject matter.

TECHNICAL AREA

The technical field relates to thick, high deflection lenses for use in lighting devices, such as solid state light source illumination devices, to which the thick high deflection lenses are optically coupled. In particular, it relates to thick, high deflection lenses made in a multi-step process from a plastic material.

GENERAL PRIOR ART

Automotive lighting devices often use powerful incandescent light sources that generate a lot of heat. These light sources are generally optically coupled to glass optical lenses because glass can withstand the heat generated and does not deform in use. However, the heat of incandescent light sources is generally too high for optical lenses made of plastic materials.

Solid-state light sources generate much less heat than incandescent light sources with the same luminous power. White LEDs are increasingly used as light sources in lighting equipment for the automotive industry, for example in headlights. Such lighting devices may include optical lenses made of plastic materials because the heat is not as strong as with incandescent light sources.

Automotive lighting devices generally use thick, high deflection lenses to project light into the area in front of the vehicle. The light beam from the light sources is projected as an enlarged image, and the lens breaks the light rays in a corresponding manner. Thick, high deflection lenses have a high ratio between the thickness of the lens at the central optical axis or the thickness of the lens at the edges. These optical lenses are thus relatively thicker in the industry in terms of the ratio between the most important optical lens dimensions compared to optical lenses in other applications.

Thick, high deflection plastic material lenses are not easily manufactured in ordinary injection molding processes, since the injection molding process itself can lead to deformations of the optically active surfaces. These lenses tend to shrink during cooling, affecting their accuracy and performance. Ultimately, the quality of thick, high deflection lenses made of plastic materials can be a problem. The use of known injection molding techniques therefore poses a challenge in terms of cost and difficulty. Other injection molding problems can adversely affect the quality of thick, high deflection lenses, particularly in terms of achieving stable batch to lot uniformity and surface accuracy.

Multi-step injection molding processes for producing plastic lenses have been used for several years. Such a method may include, for example, the use of rotary dies or shuttle dies to inject two or more layers of the same plastic material over each other with a clear interface between the individual layers. However, several applications require strict tolerances on the shape and curvature of optical lenses, which can be difficult to achieve with these known methods.

Accordingly, there is still much room for numerous improvements in this technical field.

SUMMARY

One of the aims of the proposed concept is to improve the uniformity of dimensional and functional tolerances of thick, high deflection lenses made of plastic materials made with injection molding equipment. Another object is to provide an improved process that provides competitive cycle time, uniform cooling, and optimum flow of the molten plastic material during manufacture.

In one aspect, there is provided a thick, high deflection lens for use with a lighting device having a light source, the lens comprising: a first outer lens portion having opposed first and second surfaces, the first one Surface of the first outer lens part forms a first curved active optical surface of the lens which breaks incident light rays from the light source, the second surface of the first outer lens part having a plurality of first elongated baffles; a second outer lens member having opposing first and second surfaces, the first surface of the second outer lens member forming a second active optical surface of the lens which breaks the incident light beams from the light source, the second surface of the second outer lens member having a plurality of second elongated baffles having; and a lens core portion forming an interior of the lens and embedded between the first outer lens portion and the second outer lens portion, the lens core portion having opposed first and second surfaces, the first surface of the lens core portion having a plurality of third elongated baffles and the second surface the lens core part has a plurality of fourth elongated baffles; wherein the second surface of the first outer lens portion and the first surface of the lens core portion are fused to each other, wherein the first elongate baffles are interlocked with the third elongated baffles, and wherein the second surface of the second outer lens portion and the second surface of the lens core portion are fused together; wherein the second elongate baffles are interleaved with the fourth elongated baffles, and wherein the first outer lens portion, the second outer lens portion, and the lens core portion have the same refractive index and are made of a single solidified, injection-moldable plastic material that fills the interior of the lens gaplessly to prevent refraction of the incident light rays from the light source of the elongated baffles inside the lens.

In another aspect, there is provided a thick, high deflection lens made by injection molding in a mold by injecting a single molten plastic material in at least three injections using a multi-step process, the lens comprising: a first active optical surface having a first outer edge and a second active optical surface having a second outer edge; a lens body defined between the first active optical surface and the second active optical surface for light rays to enter the lens through the first active optical surface and exit the lens through the second active optical surface, the lens body having a lens core portion; which is embedded in the interior of the lens body between a first and a second outer lens part, wherein the first active optical surface is provided on the first outer lens part, which is injection molded after the lens core part, and the second active optical surface is provided on the second outer lens part is injection-molded after the first outer lens part; a first tool-edge marker disposed on the first outer edge and a second tool-edge marker disposed on the second outer edge; a first internal flow pattern including at least two spaced and continuous streams of solidified plastics material extending completely over the lens body on one side of the lens core portion from the first tool portion; and a second internal flow pattern including at least two spaced and continuous streams extending across the lens body from the second tool gate on a different side of the lens core portion, the first and second internal flow patterns being visible by optical probes.

In another aspect, there is provided a lighting apparatus comprising: a solid-state light source; and a thick, high deflection lens that captures light from the solid state light source, the lens being constructed as previously defined.

In another aspect, there is provided a method of injection molding a thick, high deflection optical lens, the method including providing a first mold cavity formed between a first mold insert and a mandrel, the mandrel having a core injection surface, the first one Mold insert has an injection surface and at least two spaced undercuts, each of the undercuts having at least two side walls, a depth, a width and a length; Injecting a first quantity of molten plastic material into the first mold cavity through a first tool gate such that the molten plastics material flows in a direction parallel to the side walls of the undercuts and along the length of the undercuts into the first mold cavity; Cooling the plastic material in the first mold cavity, wherein the plastic material comes into cooling contact with the undercuts so that a first lens part is formed at the end of the cooling time, the first lens part having at least two elongated baffles between the undercuts, each elongate baffle surface being opposed to two has lateral surfaces; Providing a second mold cavity disposed between the first lens part and a second mold insert; and injecting a second quantity of the molten plastic material into the second mold cavity through a second tool gate aligned with the second mold cavity lateral surfaces of the elongated baffles are arranged to allow the flow of the molten plastic material along the two spaced baffles.

Details of the aspects as well as other aspects of the proposed concept will become apparent from the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

1 Fig. 12 is a cross-sectional view of an example of a thick, high-sag lens according to an embodiment of this invention, the lens being provided inside a general example of a lighting apparatus;

2 is a cross-sectional view of the thick lens with high deflection 1 wherein the two lens parts thereof have been visualized for purposes of illustration;

3 is a cross-sectional view of the thick lens with high deflection 1 wherein the two lens parts thereof have been visualized for purposes of illustration and shown as being detached from each other;

4 is an isometric view of the first lens portion of the thick lens with high deflection 1 ;

5 is an isometric view of the thick lens with high deflection out 1 after the second lens part protrudes beyond the first lens part 3 was set;

6 is a view similar to 2 Fig. 11, which illustrates another example of a thick high deflection lens according to an embodiment of this invention;

7 Fig. 12 is a photograph of a thick, high sag lens when viewed under polarized light to show the presence of the internal baffles that are otherwise invisible when, for example, the light from the light source is used;

8th Fig. 10 is a schematic view showing some dimensions of thick, high deflection lenses;

9 Fig. 12 is a schematic view showing the differences between the upper portion of two lenses, one having a small deflection and the other having a high deflection;

10 and 11 are schematic views showing the two lenses 9 during manufacture and show the cooling channels of the corresponding mold cavities;

12 to 20 show examples of injection molding equipment for making a thick, high deflection lens according to one embodiment of this invention;

21 to 26 show another example of a thick high deflection lens according to an embodiment of this invention;

27 to 32 show another example of a thick high deflection lens according to an embodiment of this invention; and

33 to 44 show another example of a thick high deflection lens according to an embodiment of this invention.

DETAILED DESCRIPTION

1 shows an example of a thick lens with high deflection 12 in an example of a headlight 10 is provided, wherein the headlight 10 is a general example of a lighting device. The headlight 10 has a protective housing and a light source 9 on, to which the lens 12 optically coupled. The light source 9 may be a solid state light source such as an LED or, more specifically, a white LED. Modifications are also possible. In use, the light source generates 9 light rays 2 that from the lens 12 to get broken.

2 is a cross-sectional view of the thick lens 12 with high deflection 1 , This lens 12 is made of a transparent plastic material. Examples of plastic materials include polymethyl methacrylate (PMMA), acrylic and polycarbonate, to name but a few. Other plastic materials may be used.

In 2 has the illustrated lens 12 a first lens part 14 and a second lens part 17 on. The lens parts 13 . 17 form the body of the lens 12 , The two lens parts 14 . 17 are visible separately for illustration purposes only. The border between the lens parts 14 . 17 otherwise it is not visible or visible to the naked eye, for example, using the light from the light source 9 , Therefore, it comes at the border between the lens parts 14 . 17 in the lens does not refract the light rays. However, the boundary is visible in polarized light, phase contrast microscopy or other visualization devices or instruments. The two lens parts 14 . 17 point the same refractive index. They are generally made of the same plastic material, but modifications are possible.

The Lens 12 has a first active optical surface 13 and a second active optical surface 18 on. At least one of the first active optical surface 13 and the second active optical surface 18 is curved, ie it has at least one curved section. This curved surface portion may, for example, be spherical, cylindrical, aspherical, parabolic or free-formed.

The second lens part 17 is attached to the first lens part during manufacture 14 fused to the thick lens with high deflection 12 to create. The term "fused" means securing or joining the lens parts together using heat from the hot molten plastic material during the manufacturing process.

Every lens part 14 . 17 has corresponding stretched baffles 14 ' . 17 ' on. The term "baffle" refers to a portion of a lens part. The baffles 14 ' . 17 ' serve to provide a multi-step manufacturing process for making the thick lens with high deflection 12 to support. These baffles 14 ' . 17 ' have ends which are the curvature of the active optical surface 18 consequences. When to make the thick lens with high deflection 12 are fused to each other, are the baffles 14 ' . 17 ' entangled or alternate in a cross section without an air gap therebetween and without the illumination power of the lens 12 to impair. Thus, the plastic material fills the entire volume of the lens 12 ,

3 is a cross-sectional view of the thick lens with high deflection 1 where the two lens parts 14 . 17 were made visible for illustration purposes only and are shown as detached from each other. After the manufacturing process form the first lens part 14 and the second lens part 17 a monolithic piece and can not be separated.

As can be seen, the lens parts exhibit 14 . 17 an equal or nearly equal thickness, defined as "T". The thickness (ie width) of the baffles 14 ' may also be the same or comparable. Likewise, the thickness (ie width) of the baffles 17 ' be the same or comparable. The thickness of the baffles 14 ' . 17 ' is also the same as or comparable to the thickness "T". These features provide for a more even cooling during manufacture. Nevertheless, modifications are possible.

4 is an isometric view of the first lens part 14 the thick lens 12 with high deflection 1 , As can be seen, the first elongated baffles point 14 ' two opposite lateral surfaces 140 on, with the baffles 14 ' a surface 142 and an upper section 144 exhibit. The first lens part 14 has a first tool gate 13 ' on. The first tool cutting 13 ' indicates the position where the molten plastic material was injected into the corresponding mold cavity during manufacture.

5 is an isometric view of the thick lens 12 with high deflection 1 after the second lens part 17 over the first lens part 14 out 3 was set. 5 also shows that the lens 12 a second tool gate 18 ' having. The second tool gate 18 ' indicates the position where the molten plastic material was injected into the corresponding mold cavity during manufacture. The baffles 14 ' of the first lens part 14 are parallel or nearly parallel and have elongated lateral surfaces 140 on, the spacing sections 14 '' define at the second tool gate 18 ' are aligned. The first baffles 14 ' and the second baffles 17 ' are over the entire length of the side surfaces 140 the first baffles 14 ' interlocked as soon as the lens 12 is completed.

6 is a view similar to 2 which is another example of a thick lens with high deflection 12 according to one embodiment of this invention. 6 shows that the tips of the baffles 14 ' an imaginary curved line 28 essentially define the curvature of the second active optical surface 18 follows.

7 Figure 5 is a photograph of an example of a thick, high sag lens 12 when viewed under polarized light, the presence of internal baffles 14 ' . 17 ' to show. The border between the baffles 14 ' . 17 ' otherwise it is not visible, such as using light from the light source 9 out 1 , Thus, the baffles 14 ' . 17 ' not usually seen, and the lens 12 is when viewed by an observer using the light from the light source 9 completely transparent on the optical axis.

The deflection of a spherical lens defines the curvature of the depth of the lens as a function of the lens radius and the lens thickness on the optical axis. The lens thickness decreases in the case of the thick lens with high deflection from the center to the edge of the lens.

R

der Krümmungsradius der zweiten aktiven optischen Oberfläche 18 ist; und

r

der Radius der Linse 12 senkrecht zur optischen Achse ist.

8th is a schematic view showing some dimensions of thick lenses with high Deflection shows. The sag of the lens 8th can be defined as: Deflection = R - Sqrt [R ² - r ² ] in which:

R

the radius of curvature of the second active optical surface 18 is; and

r

the radius of the lens 12 perpendicular to the optical axis.

9 Fig. 13 is a schematic view showing the differences between the upper portion of two optical lenses, one having a small deflection and the other having a higher deflection. lens 3 is a lens with low deflection and lens 4 is a lens with high deflection. The lenses 3 . 4 are defined by an outer diameter OD corresponding to the numerical aperture NA of the lenses 3 . 4 is equivalent.

10 and 11 are schematic views showing the two lenses 3 . 4 out 9 during manufacture and show the cooling channels of the corresponding mold cavities.

The lens with low deflection 3 out 10 is from upper cooling channels 5 and lower cooling channels 7 surround. The distance between the upper and lower cooling channels 5 . 7 is on the lens with little deflection 3 relatively constant. This facilitates the cooling of the lens 3 during manufacture, since their thickness is relatively uniform from the middle to the edges.

The lens with high deflection 4 out 11 has a relatively steep change in thickness from the center to the edges. This is the distance between the upper and lower cooling channels 5 ' . 7 ' this lens 4 less even than that of the cooling channels 5 . 7 the lens with low deflection 3 , The shaping of this high lens 4 in a single step, cooling makes it harder to control and predict. The thinner plastic material at the edges of the lens 4 often cools faster than the thicker plastic material in the center of the lens 4 , causing the cooling of the lens 3 is almost unpredictable and creates distortions that can affect the quality of the active optical surfaces.

12 to 20 show examples of injection molding equipment for making a thick, high deflection lens according to one embodiment of this invention.

12 is a cross-sectional view of a first mold insert 50 and a corresponding mold core 52 , A first cavity 56 is between the mold insert 50 and the mandrel 52 provided to receive the hot molten plastic material, the first lens part during the first injection process 14 will form.

13 is a cross-sectional view of the same mold insert 50 and the same mold core 52 , opposite to the presentation 12 considered offset by 90 °. The molten plastic material is passed through a sprue 57 and then a first cavity mold 58 injected. The mold insert 50 has several undercuts 54 on that the baffles 14 ' on the first lens part 14 of the illustrated example.

The first mold insert 50 has a number of cooling channels 51 on, and also the mold core 52 has a number of cooling channels 53 on. Both cooling channels 51 . 53 each follow the shape of the active optical surfaces 18 respectively. 13 ,

In the first mold cavity 56 are the undercuts 54 by spacing sections 54 ' separated from each other, the forming channels in the first mold cavity 56 produce. The forming channels and thus the undercuts 54 are at the first mold cavity gantry 58 Aligned so that the hot molten plastic material can flow without turbulence in one direction, the complete direct venting of the first mold cavity 56 allowed while the molten plastic material is injected. The molten plastic material fills the entire volume of the first mold cavity 56 , as in 14 shown.

After filling the first mold cavity 56 with molten plastic material becomes the first lens part 14 in the first mold cavity 56 cooled, with the first mold insert 50 and the mold core 52 stay in a closed position. The undercuts 54 provide an increased area that facilitates heat transfer between the first lens portion 14 and the cooling channels 51 promotes. This shortens the cooling time.

After cooling, the same mold core 52 and the first lens part 14 which has just been formed thereon, for producing the second lens part 17 used. A second mold insert 55 is provided to a second mold cavity 64 to produce, as in 15 and 16 shown. The baffles 14 ' of the first lens part 14 are so on the second mold cavity gate 61 aligned such that a second injection of the molten plastic material into the second mold cavity 64 flows and this fills while a Formfüllweg on the side surfaces of the baffles 14 ' follows.

When the second injection of the molten plastic material occurs, the stretched baffles become 17 ' that with the rest of the second lens part 17 be produced by overmolding injection to the baffles 14 ' melted. The baffles 14 ' create channels that allow the discharge of air and gas from the second mold cavity 64 allow as in 17 shown. As can be seen, the melt stream is moving 6 between the baffles 14 ' in the space 14 '' forward and generates a series of currents 3 ' , Because the flow between the baffles 14 '' is not obstructed, flows the molten plastic material without turbulence, and the second mold cavity 64 is filled with appropriate venting, by the orientation of the baffles 14 ' with respect to the second tool gate 61 is possible. This prevents bubbles in the second lens part 17 and between the two lens parts 14 . 17 form what the quality of the lens 12 significantly improved. The molten plastic material fills the entire volume of the second mold cavity 64 , as in 18 shown.

19 Figure 12 is a semi-schematic isometric view showing an example of a rotary die tool intended to make a thick high deflection lens according to an embodiment of this invention. This rotary forming tool has a first mold insert 50 , a second mold insert 55 and two corresponding mandrels 52 on. The first mold insert 50 and the second mold insert 55 are under a turntable 20 provided, which can be repositioned after each manufacturing step. The turntable 20 can be raised, swiveled 180 ° and back on the mandrels 52 be lowered. The different parts are configured in this way and arranged accordingly.

20 FIG. 12 is a cross-sectional view of an example of injection molding equipment based on the principle of the present invention. FIG 19 are shown. It has a nozzle 40 which injects the molten plastic material into the two mold cavities. The first mold cavity forms the first lens part 14 between molding surfaces 43 and 44 , After the first injection process, the rotary plate 20 moved to a second position to the second lens part 17 between the first lens part 14 and the molding surface 45 of the second mold insert 55 to shape. Also modifications are possible.

As will be understood, the design of the lens of the invention aids in the molding process, such that the first lens portion 14 and the second lens part 17 have thinner surfaces than the thick lens with high deflection 12 , and these surfaces have an equal or comparable thickness T.

21 to 26 show another example of a thick lens with high deflection 12 according to an embodiment of this invention. 21 is an isometric view of this lens 12 and 22 is a plan view on it. 23 is a cross-sectional view of the lens 12 along the line 23-23 22 , 24 is an isometric view showing different parts of the lens 12 out 21 which have been separated for purposes of illustration. 25 is an isometric partial sectional view of the lens 12 out 21 , 26 is an isometric view showing the different parts of the lens 12 out 25 which have been separated for purposes of illustration.

21 to 26 show that the lens 12 has three lens parts, namely a first outer lens part 200 , a second outer lens part 210 and a lens core part 220 , The lens core part 220 is completely between the first outer lens part 200 and the second outer lens part 210 embedded. This configuration greatly improves the quality of thick, high deflection lenses with relatively high deflection, for example, up to 40mm deflection. The first outer lens part 200 , the second outer lens part 210 and the lens core part 220 have the same refractive index and are made from a single solidified injection moldable plastic material. The plastic material fills the interior of the lens 12 completely refractory to a refraction of incident light rays from the light source through one of the elongated baffles in the body of the lens 12 to prevent. The light source may be, for example, the light source 9 out 1 be. Also modifications are possible.

The first outer lens part 200 has an opposite first and second surface. The first surface of the first outer lens part 200 defines the first curved active optical surface 13 the lens 12 which refracts incident light rays from the light source. The first curved active optical surface 13 is one of the external surfaces of the lens 12 , The second surface of the first outer lens part 200 has several first elongated baffles 202 on. The second surface is in the lens 12 embedded.

The second outer lens part 210 also has an opposite first and second surface. The first surface of the second outer lens part 210 defines the second curved active optical surface 18 the lens 12 which breaks the incident light rays from the light source. The second curved active optical surface 18 is one of the external surfaces of the lens 12 , The second surface of the second outer lens part 210 has several second elongated baffles 212 on. The second surface is in the lens 12 embedded.

The lens core part 220 has an opposite first and second surface. The first surface of the lens core part 220 has several third elongated baffles 222 on, and the second surface of the lens core part 220 has several fourth elongated baffles 224 on. The first and second surfaces are in the lens 12 embedded.

During production, the lens core part is first 220 molded in the appropriate mold cavity. The lens core part 220 it does not have to be very precise in terms of its dimensions, as it is completely inside the lens at the end of the manufacturing process 12 will be embedded. In this way, the lens core part 220 be made thicker in the middle. The baffles on both sides of the lens core 220 improve heat transfer with the mold during manufacture.

After shaping the lens core part 220 becomes the first outer lens part 200 directly over one side of the lens core part 220 shaped. The second surface of the first outer lens part 200 and the first surface of the lens core part 220 are then fused together, with the first elongated baffles 202 with the third stretched baffles 222 to be crossed. Then the second outer lens part becomes 210 over the opposite side of the lens core part 220 shaped. The second surface of the second outer lens part 210 and the second surface of the lens core part 220 are fused together, the second elongated baffles 212 with the fourth stretched baffles 224 to be crossed.

As can be seen, the different baffles point in the lens 12 all in the same direction. Modifications are also possible.

27 to 32 show another example of a thick lens with high deflection 12 according to an embodiment of this invention. 27 is an isometric view of this lens 12 and 28 is a plan view on it.

29 is a cross-sectional view of the lens 12 along the line 29-29 28 , 30 is an isometric view showing different parts of the lens 12 out 27 which have been separated for purposes of illustration. 31 is an isometric partial sectional view of the lens 12 out 27 , 32 is an isometric view showing the different parts of the lens 12 out 31 which have been separated for purposes of illustration.

27 to 32 show that this lens 12 a similar configuration as the lens 12 out 21 to 26 having. However, the lens core part is 220 from two subsections 220A . 220B formed, which are over-molded. Each subsection 220A . 220B has crossed baffles 226 . 228 on. It is also possible to use more than two subsections. In this example, the subsection was first 220A made at the bottom of the view.

As can be seen, the different baffles point in the lens 12 all in the same direction. Modifications are also possible.

33 to 44 show another example of a thick lens with high deflection 12 according to an embodiment of this invention. 33 is an isometric view of this lens 12 and 34 is an isometric partial sectional view of the lens 12 out 33 , 35 is a top view of the lens 12 and 36 is a cross-sectional view of the lens 12 along the line 36-36 35 , 37 and 38 are isometric views representing the different parts of the lens 12 show as shown in 33 which have been separated for purposes of illustration. 39 is an isometric view showing the different parts of the lens 12 out 34 which have been separated for purposes of illustration.

40 to 44 show the core lens part 220 the lens 12 out 33 to 39 , 40 is a plan view, 41 is a side view of it, 42 is a bottom view of it, 43 is an isometric top view on it and 44 is a view similar to 43 but with a partially cut open section.

The shape of the lens 12 out 33 to 44 is more complex than the shape of the lenses 12 in the preceding examples. The lens core part 220 for this lens 12 has radially arranged stretched baffles 222 on the side on, the first outer lens part 200 is facing. This page is the bottom in the example shown. The baffles 222 are more triangular near the middle 223 and get bigger towards the outer edge. The outer portion of the baffles 222 is also thicker than the outer edge. The lens core part 220 is thus a rough design, over which the highly precise active optical surfaces 13 . 18 using the outer lens part 200 . 210 be formed.

When manufacturing the first outer lens part 200 the lens 12 , the hot molten plastic material is injected into the center of the mold cavity. The melt flows radially from the center 223 between the radially arranged elongate baffles 222 of the lens core part 220 , Of the opposite lens core part 220 the lens shown 12 has baffles 224 on, which is parallel to each other.

The embodiments are applicable to lighting devices in many applications, including vehicles. Lighting devices for vehicles include, for example, headlights and fog lights, to name but a few. The thick high deflection lenses can be used as dimming lenses, high beam lenses and fog lenses. The following examples show some of the dimensions required for a thick, high deflection lens according to this invention. These dimensions are for informational purposes, and smaller or larger lenses may also be constructed or fabricated in accordance with the teachings of the invention. The values in the following examples are in millimeters. L is the length of the lens 12 and W is the width of the lens because they are not circular. In other embodiments, the length L may be considered as the single diameter of a circular lens, in embodiments, the width W may be considered as the single diameter of a circular lens, and the values given above also apply to these round or circular lenses.

Low / high beams lenses:

• Example 1: L100 × W60 × thickness (maximum 30 mm-min 4 mm), thickness ratio: 7.5: 1 and deflection: 26 mm
• Example 2: L135 × W40 × thickness (max 18.5 mm-min 1 mm), thickness ratio: 18.5: 1 and deflection: 18 mm

• Beispiel 3: L50 × W30 × Dicke (max. 12 mm–min. 2 mm), Dickenverhältnis: 6:1 und Durchbiegung: 10 mm
• Beispiel 4: L45 × W40 × Dicke (max. 13 mm–min. 2 mm), Dickenverhältnis: 6,5:1 und Durchbiegung: 11 mm

For circular / round lenses, the diameters are in the range L and W given above, and the corresponding thicknesses, sag values and thickness ratios: Front fog lenses:

• Example 3: L50 x W30 x thickness (max 12 mm-min 2 mm), thickness ratio: 6: 1 and sag: 10 mm
• Example 4: L45 × W40 × thickness (maximum 13 mm-min 2 mm), thickness ratio: 6.5: 1 and deflection: 11 mm

The presented detailed description and the accompanying figures are intended to serve as examples only. One skilled in the art will recognize that modifications may be made in light of the present disclosure without departing from the suggested concept. It should be noted that the word "where" used herein is not intended to be limiting.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• CA 2011/000129 [0001]

Claims (9)

A high deflection, thick lens for use with a lighting device having a light source, the lens comprising: a first outer lens member having opposed first and second surfaces, wherein the first surface of the first outer lens member forms a first curved active optical surface of the lens which refracts incident light rays from the light source, the second surface of the first outer lens member having a plurality of first elongated baffles ; a second outer lens portion having opposing first and second surfaces, the first surface of the second outer lens portion forming a second active optical surface of the lens which breaks the incident light rays from the light source, the second surface of the second outer lens portion having a plurality of second elongate baffles having; and a lens core portion forming an interior of the lens and embedded between the first outer lens portion and the second outer lens portion, the lens core portion having opposing first and second surfaces, the first surface of the lens core portion having a plurality of third elongated baffles and the second surface of the lens core portion Linsenkernteils several fourth elongated baffles has; wherein the second surface of the first outer lens portion and the first surface of the lens core portion are fused to each other, wherein the first elongate baffles are interlocked with the third elongated baffles, and wherein the second surface of the second outer lens portion and the second surface of the lens core portion are fused together; wherein the second elongated baffles are interleaved with the fourth elongated baffles, and wherein the first outer lens portion, the second outer lens portion, and the lens core portion have the same refractive index and are made of a single solidified, injection-moldable plastic material that fills the interior of the lens gaplessly Refraction of the incident light rays from the light source of the elongated baffles inside the lens is refracted. The lens of claim 1, wherein the first elongated baffles and the second elongated baffles are parallel to each other. The lens of claim 1, wherein the first elongated baffles and the third elongated baffles extend substantially radially inside the lens. The lens of claim 1, wherein the lens core portion is made of two over-molded subsections, the subsections having interleaved baffles therebetween. A high deflection, thick lens made by injection molding in a mold by injecting a single molten plastic material in at least three injections using a multi-step process, the lens comprising: a first active optical surface having a first outer edge and a second active optical surface having a second outer edge; a lens body defined between the first active optical surface and the second active optical surface for light rays to enter the lens through the first active optical surface and exit the lens through the second active optical surface, the lens body having a lens core portion; which is embedded in the interior of the lens body between a first and a second outer lens part, wherein the first active optical surface is provided on the first outer lens part, which is injection molded after the lens core part, and the second active optical surface is provided on the second outer lens part is injection-molded after the first outer lens part; a first tool-edge marker disposed on the first outer edge and a second tool-edge marker disposed on the second outer edge; a first internal flow pattern including at least two spaced and continuous streams of solidified plastics material extending completely over the lens body on one side of the lens core portion from the first tool portion; and a second internal flow pattern including at least two spaced and continuous streams extending across the lens body from the second tool gate on another side of the lens core portion, the first and second internal flow patterns being visible by means of optical probes. The lens of claim 5, wherein the lens core portion is made of two over-molded subsections. Lighting device, comprising: a solid state light source; and a thick, high deflection lens which captures light from the solid state light source, the lens being constructed as defined in any one of claims 1 to 6. The lighting apparatus according to claim 7, wherein the solid-state light source includes an LED. Lighting apparatus according to claim 7 or 8, wherein the solid-state light source and the thick lens are provided with high deflection in the interior of a vehicle headlight.

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