Method for producing optical component

Abstract

The invention relates to a method (1) for producing an optical component (2), characterized in that the production method (1) comprises: a first step of injection molding a first core (20.1), the first core (20.1) extending in a first direction; -a second step of injection molding of a first outer layer (21.1) encapsulating the first core (20.1), the first core (20.1) and the first outer layer (21.1) forming a second core (20.2), characterized in that the first step of injection molding of the first core (20.1) comprises injection molding of first tabs (200.1) on both sides of the first core (20.1) in a second direction perpendicular to the first direction.

Description

[0001] This invention relates to a method for manufacturing optical components. It also relates to a light-emitting device for vehicles, comprising optical components manufactured by the aforementioned method, and to a rotary mold for manufacturing the optical components. The invention is particularly, but not limited to, motor vehicles.

[0002] A method known to those skilled in the art for manufacturing optical components (such as lenses) includes: - The first step in injection molding the core - The step of injection molding a first outer layer, which encapsulates a first core, the first core and the first outer layer forming a second core.

[0003] Therefore, multiple layers are obtained. The injection molding steps used to form the layers are as many as those required to form the optical components.

[0004] The disadvantage of this prior art is that, due to the injection molding pressure, the first core may rock forward or backward as the material is just being injected around it.

[0005] In this context, the present invention aims to provide a production method that enables the resolution of at least one of the aforementioned disadvantages.

[0006] Therefore, the present invention provides a method for manufacturing optical components, characterized in that the manufacturing method includes: - The first step in injection molding the first core, wherein the first core extends along a first direction. - A second step of injection molding a first outer layer, the first outer layer encapsulating the first core, the first core and the first outer layer forming a second core, characterized in that the first step of injection molding the first core includes injection molding first tabs on both sides of the first core along a second direction perpendicular to the first direction.

[0007] The first tab is configured to prevent the first core from rocking about an axis that is substantially parallel to a second direction and perpendicular to the first direction when the first outer layer is injection molded.

[0008] Therefore, as will be seen in detail below, the first tab ensures the stability of the optical component in the mold between injection molding steps. The first tab also prevents deformation caused by the core shifting, thus improving the quality of the final part.

[0009] According to a non-limiting embodiment, the production method may additionally have one or more of the following additional features, either individually or in any technically possible combination.

[0010] According to a non-limiting embodiment, the first tab is elongated along the second direction.

[0011] According to a non-limiting embodiment, the first tab has an elongated shape in a cross-section passing through a plane perpendicular to the second direction.

[0012] According to a non-limiting embodiment, at least two first tabs are injection molded on at least one side of the first core.

[0013] According to a non-limiting embodiment, the second step of injection molding the first outer layer is performed by means of a material injection channel disposed between the at least two first tabs.

[0014] According to a non-limiting embodiment, the production method further includes the following steps, where n is an integer ranging from 2 to N, where N>=3: - The (2n-1)th step of injection molding the nth tab, which extends in a second direction on both sides of the nth core, the step of injection molding the nth tab is part of the step of injection molding the (n-1)th outer layer. - Step 2n of injection molding the nth outer layer, which encapsulates the nth core, the nth core and the nth outer layer forming the (n+1)th core.

[0015] According to a non-limiting embodiment, for n>=3, the 2n-1th injection molding step is optional.

[0016] Throughout the instruction manual, the symbol ">=" means greater than or equal to.

[0017] According to a non-limiting embodiment, the nth tab is located away from the (n-1)th tab.

[0018] According to a non-limiting embodiment, the nth tab is away from all pth tabs, where p takes any integer value between 1 and n-1.

[0019] According to a non-limiting embodiment, the manufacturing method further includes the step of cutting the first tab.

[0020] According to a non-limiting embodiment, the production method further includes the step of cutting the nth tab, or some of the tabs among the nth tabs.

[0021] According to a non-limiting embodiment, the optical component includes a light incident area configured to face the light source, and the optical component includes a light exiting area.

[0022] According to a non-limiting embodiment, the optical component has an optical axis that is substantially perpendicular to the second direction.

[0023] According to a non-limiting embodiment, the production method includes the step of cutting the material injection channel.

[0024] According to a non-limiting embodiment, the length of the first core extends along a first direction.

[0025] According to a non-limiting embodiment, the width of the first core extends along a second direction.

[0026] According to a non-limiting embodiment, the width of the first core is greater than its thickness extending upward in a third direction.

[0027] According to a non-limiting embodiment, the optical component includes a cutoff region.

[0028] According to a non-limiting embodiment, the optical component includes a light-reflecting region in which light is reflected by total internal reflection.

[0029] According to a non-limiting embodiment, the optical component includes at least one collimator.

[0030] According to a non-limiting embodiment, the optical component has a light-emitting surface, which is a lens.

[0031] The present invention also provides a light-emitting device for a vehicle, the light-emitting device comprising an optical component manufactured by a production method according to any one of the above features, and at least one light source. The light source is specifically arranged to face the light incident area of ​​the optical component and is capable of emitting light in a direction toward the light incident area.

[0032] According to a non-limiting embodiment, the light-emitting device is a headlight, a taillight, or an interior lighting device.

[0033] The present invention also provides a rotary production mold for optical components, characterized in that the rotary mold includes at least two injection molding stations and at least two mold cavities configured to receive the optical components during corresponding steps in the production of the optical components.

[0034] According to the present invention, a first injection molding station is configured to perform a first injection molding step of the production method according to the present disclosure, and a second injection molding station is configured to perform a second injection molding step of the production method according to the present disclosure.

[0035] According to a non-limiting embodiment, the rotary mold includes three injection molding stations.

[0036] According to a non-limiting embodiment, the rotary mold further includes at least two cooling stations.

[0037] According to a non-limiting embodiment, the rotary mold includes two injection molding stations, that is, each of the two first injection molding steps corresponds to one injection molding station, and when n>=2, an injection molding station is added for each 2nth injection molding step.

[0038] According to a non-limiting embodiment, the rotary mold includes the same number of injection molding cavities as the injection molding stations.

[0039] According to a non-limiting embodiment, the rotating mold includes a demolding axis that is perpendicular to the optical axis of the optical component.

[0040] According to a non-limiting embodiment, the rotary mold includes at least one slider in the injection molding cavity associated with the 2Nth injection molding step. This allows for the limitation of the risk of mold closure marks in the optical functional and / or aesthetic portions of the optical component.

[0041] A better understanding of the invention and its various applications will be gained by reading the following description and studying the accompanying drawings: [ Figure 1a [This is a flowchart of the steps of a method for producing an optical component according to a non-limiting embodiment of the present invention, the optical component comprising at least one core and two outer layers.] [ Figure 1b [This is a flowchart of the steps of a method for producing an optical component according to a non-limiting embodiment of the present invention, the optical component comprising at least one core and a plurality of outer layers.] [ Figure 2 ] is through Figure 1a and Figure 1b A perspective view of a first non-limiting embodiment of an optical component produced by the manufacturing method described above, the optical component including a first core, a first outer layer, and a second outer layer. [ Figure 3 ]yes Figure 2 A perspective view of a first non-limiting embodiment of an optical component having a first core with a first protrusion. [ Figure 4 [This is a view of the longitudinal section of the previous figure.] [ Figure 5 ]yes Figure 2 A perspective view of a first non-limiting embodiment of the first outer layer of the optical component, the first outer layer encapsulating... Figure 3 The first core in the middle, and together with the first core, form the second core. [ Figure 6 [This is a view of the longitudinal section of the previous figure.] [ Figure 7 ]yes Figure 2 A perspective view of a first non-limiting embodiment of the second outer layer of the optical component, the second outer layer encapsulating... Figure 5 The second core in the middle, [ Figure 8 [This is a view of the longitudinal section of the previous figure.] [ Figure 9 ] is through Figure 1a and Figure 1b A perspective view of a second non-limiting embodiment of an optical component produced by the manufacturing method described herein. Figure 10 ]yes Figure 9 A perspective view of a second non-limiting embodiment of an optical component having a first core with a first protrusion. [ Figure 11 [This is a view of the longitudinal section of the previous figure.] [ Figure 12 ]yes Figure 9 A perspective view of a second non-limiting embodiment of the first outer layer of the optical component, the first outer layer encapsulating... Figure 10 The first core in the middle, and together with the first core, form the second core. [ Figure 13 [This is a view of the longitudinal section of the previous figure.] [ Figure 14 ]yes Figure 2 A view of a second non-limiting embodiment of the second outer layer of the optical component, the second outer layer encapsulating... Figure 12 The second core in the middle, [ Figure 15 [This is a view of the longitudinal section of the previous figure.] [ Figure 16 [Illustration] is a schematic diagram of a vehicle equipped with a light-emitting device including optical components according to the present invention. [ Figure 17 ] is used to pass Figure 1a and Figure 1b A schematic diagram of a rotating mold used in the production method of optical components.

[0042] Unless otherwise specified, elements that are identical in structure or function and appear in different figures are indicated by the same reference numerals.

[0043] refer to Figure 1a and Figure 1b A method 1 for manufacturing an optical component 2 according to the present invention is described, and reference is made to... Figures 2 to 16 The manufactured optical component 2 is described. In a non-limiting embodiment, the optical component 2 is used in a vehicle 3 (in... Figure 16 The optical components are shown in the image. In a non-limiting embodiment, vehicle 3 is a motor vehicle.

[0044] Optical component 2 can be integrated into light-emitting device 4 (in Figure 16(Schematively shown in the diagram), the light-emitting device also includes at least one light source 40. This at least one light source is arranged to face the optical component 2. In a non-limiting embodiment, the light-emitting device 4 is a headlight, taillight, or interior lighting device for a motor vehicle 3. Figure 16 In the non-limiting example shown, optical component 2 is integrated into the headlight.

[0045] In one non-limiting embodiment, the at least one light source 40 is a semiconductor light source. In one non-limiting embodiment, the semiconductor light source is formed as part of a light-emitting diode or a laser diode. "Light-emitting diode" means any type of light-emitting diode, whether in this non-limiting example, an LED, an OLED (organic LED), an AMOLED (active-matrix organic LED), or a FOLED (flexible OLED). The at least one light source 40 is configured to generate light R.

[0046] Optical component 2 has Figure 2 and Figure 9 The optical axis is shown as A-A'. The length of the optical component extends in the first direction X (also referred to as the elongation direction), the width of the optical component extends in the second direction Y (also referred to as the transverse direction Y) perpendicular to the first direction X, and the thickness of the optical component extends in the third direction Z (also referred to as the thickness direction Z) perpendicular to the first direction X and the second direction Y.

[0047] Optical component 2 includes a light incident area 23 configured to face the at least one light source 40 and receive light rays R emitted by the light source 40. Optical component 2 includes a light exit area 24 through which a light beam Fx formed by the light rays R can exit. The light beam Fx again exits substantially along the optical axis A-A'. "Substantially along the optical axis" means that the light beam defines what is commonly referred to as a light cone, and the optical axis lies within the light cone. The light cone has a diffusion angle, which may vary depending on the direction in question.

[0048] In a non-limiting embodiment (not shown), the optical component 2 forms a projection lens, also referred to as a lens. In this case, the optical component 2 has a simple and conventionally symmetrical shape.

[0049] exist Figure 2 and Figure 9 In another non-limiting embodiment shown, the optical component 2 includes at least one collimator 26 and a light-reflecting region 27, in which light is reflected specifically by total internal reflection. The optical component 2 has a light-exiting surface 28, which is a lens. The lens 28 is a refractive interface located at one end of the optical component 2. In this case, it can be seen that the optical component 2 has a complex and asymmetrical shape. Figure 9In one non-limiting embodiment shown, the optical component 2 includes a cutoff region 29. The cutoff region 29 is configured to create a cutoff in the light beam projected by the optical component 2, manufactured by production method 1, when the light source 40 is in its operating position and turned on. In this non-limiting embodiment, the light beam R from the light source 40 enters the optical component 2 via collimator 26 and is reflected at reflector 27 to form a light beam Fx, which is guided along the optical axis A-A' toward lens 28 and exits again via light exit region 24.

[0050] Optical component 2 is a thick component. In one non-limiting embodiment, the thickness of the optical component is between 5 mm and 50 mm. In another non-limiting embodiment variant, the thickness of the optical component is between 10 mm and 40 mm. In yet another non-limiting embodiment variant, the thickness of the optical component is between 14 mm and 37 mm.

[0051] Optical component 2 includes: - First core 20.1, - A first outer layer 21.1 encapsulates a first core 20.1, and the first outer layer 21.1 and the first core form a second core 20.2.

[0052] In the remainder of the specification, reference numeral 20 is generally used to denote the core, and reference numeral 21 is generally used to denote the outer layer. Reference numerals 20.1, 20.2, ..., 20.n are used to denote the first core, the second core, and the nth core. Reference numerals 21.1, 21.2, ..., 21.n are used to denote the first outer layer, the second outer layer, and the nth outer layer.

[0053] It should be noted that when the optical component 2 has a considerable thickness, having multiple stacked layers is advantageous. This allows for a reduction in the time required for the material to solidify during injection molding. This is because a component injection molded from a very thick block requires a significant amount of time to cool down to the center, while each layer can cool rapidly, and the total time required for all layers to cool sequentially is much shorter than the time required for an equivalent block to cool.

[0054] In a non-limiting embodiment, the optical component 2 further includes: - Second outer layer 21.2, which encapsulates the second core 20.2.

[0055] In one non-limiting embodiment, the optical component 2 includes at least two outer layers 21.

[0056] The second outer layer 21.2 is shown in Figure 7 (It is a three-dimensional image) and Figure 8 In the first non-limiting embodiment (which is a cross-sectional view); in Figure 10 (It is a three-dimensional image) and Figure 11 In the second non-limiting embodiment (which is a cross-sectional view); and in Figure 14 (It is a three-dimensional image) and Figure 15 In the third non-limiting embodiment (which is a cross-sectional view).

[0057] In a non-limiting embodiment, the optical component 2 may have more than two outer layers.

[0058] See below for reference Figure 1a and Figure 1b In one non-limiting embodiment, a method 1 for manufacturing an optical component 2 is described, wherein the manufacturing method 1 enables the production of an optical component 2 having at least the following: - First core 20.1, and - First outer layer 21.1, and - Second core 20.2 and second outer layer 21.2.

[0059] In order to manufacture an optical component 2 having a first core 20.1, a first outer layer 21.1, a second core 20.2, and a second outer layer 21.2, the manufacturing method 1 therefore includes the following steps, such as... Figure 1a What is shown.

[0060] exist Figure 1a In the first step E1, shown as F1(20.1, 200.1), a first core 20.1 is injection molded. The length of the first core 20.1 extends along the elongation direction X. The width of the first core extends along the lateral direction Y. The width of the first core is greater than its thickness extending in the thickness direction Z. In a non-limiting embodiment, the injection molded material is made of PC (polycarbonate), PMMA (polymethyl methacrylate), or polyamide, or any other transparent optical material.

[0061] The first chip, 20.1, was showcased. Figure 3 (It is a three-dimensional image) and Figure 4 In the first non-limiting embodiment (which is a cross-sectional view); and in Figure 10 (It is a three-dimensional image) and Figure 11 In the second non-limiting embodiment (which is a cross-sectional view), it can be noted that... Figure 10 and Figure 11 In the middle, the first core 20.1 has a bevel 200.9, which allows for the acquisition of Figure 9 The cutoff area shown is 29.

[0062] like Figure 3 and Figure 10 As can be seen from the illustration, the first core 20.1 has an asymmetrical shape. Furthermore, the shape of the first core is complex, and it particularly has abrupt changes in thickness.

[0063] The first core 20.1 is injection molded simultaneously with the first protrusion 200.1.

[0064] In one non-limiting embodiment, the first tab 200.1 extends along a second direction Y perpendicular to the thickness direction Z of the first core 20.1 on both sides of the first core 20.1. The first tab 200.1 is perpendicular to the first direction X. In one non-limiting embodiment, the first tab 200.1 is elongated along the second direction Y. In one non-limiting embodiment, the thickness of the first tab 200.1 in a cross-section passing through a plane perpendicular to the second direction Y is substantially equal to the thickness of the first core 20.1. This avoids bending of the first tab 200.1 and thus allows the first core to be held in place when it is overmolded during the injection molding of the next layer.

[0065] Due to the injection molding pressure, the first core 20.1 may rock forward or backward as the material is just being injection molded around it. The first tab 200.1 is configured to prevent the first core 20.1 from pivoting forward or backward. The first tab holds the first core and prevents movement of the first core during injection molding of the first outer layer 21.1. Specifically, the first tab 200.1 is configured to prevent the first core from pivoting around an axis E-E' substantially parallel to the second direction Y during injection molding of the first outer layer 21.1. Figure 3 and Figure 10 (As shown) shaking. In fact, when rotating the production mold 6 ( Figure 17 When closed (as shown), these first tabs 200.1 are held by the rotary production mold, particularly by fixed and movable portions that close on these first tabs 200.1. Thus, the first tabs 200.1 are clamped (i.e., held) in and thus held by the rotary production mold 6, which is conventionally made of steel, thereby allowing the first core 20.1, arranged in the mold cavity of the rotary production mold 6 but not held by the rotary production mold, to be held on both sides but float within the mold cavity. In a non-limiting embodiment, the production mold includes three cavities labeled 61.1, 61.2, and 61.3 for receiving the first core 20.1.

[0066] The position of the first tab 200.1 depends on the results of structural calculations derived from upstream rheological simulations. This allows the correct distance for positioning the first tab 200.1 on a given layer to avoid wobbling during overmolding with the second layer. The center of rotation, the deformation amplitude of the insert (core) during overmolding, and thus the assembly of the structural reinforcement with these first tabs 200.1 are identified.

[0067] In a non-limiting embodiment, the first tab 200.1 has an elongated shape in a cross-section passing through a plane perpendicular to the second direction Y. Therefore, when only two first tabs 200.1 are present (i.e., two tabs centered on the axis E-E' and one on each side of the first core 20.1), the first core 20.1 is prevented from rocking.

[0068] In one non-limiting embodiment, at least two first tabs 200.1 are injection molded on at least one side of the first core 20.1. Figure 3 and Figure 10 In one non-limiting embodiment variation shown, at least two first tabs 200.1 are injection molded on each side of the first core 20.1. Therefore, there are four first tabs 200.1, two on one side of the first core 20.1 and the other two on the other side. This prevents the first core 20.1 from rocking. Figure 5 and Figure 12 In one non-limiting embodiment shown, two first tabs 200.1 on one side of the first core 20.1 are spaced apart to allow for the option of having a first material injection channel 25.1. Therefore, in one non-limiting embodiment, the first material injection channel 25.1 is arranged between at least two first tabs 200.1. Thus, an injection point I exists between the two first tabs 200.1. This first material injection channel 25.1 is used for injection molding the first outer layer 21.1.

[0069] exist Figure 1a In step E2, shown as F2(21.1, 200.2), a first outer layer 21.1 is injection molded, which encapsulates the first core 20.1. It should be noted that the first outer layer 21.1 does not encapsulate the first tab 200.1. The first core 20.1 and the first outer layer 21.1 form a second core 20.2, which is located in… Figure 6 and Figure 13 Reference numerals are provided in the accompanying drawings. In a non-limiting example, the first outer layer 21.1 has a thickness substantially equal to 3 mm. Therefore, since the first outer layer 21.1 is positioned completely around the first core 20.1, a total thickness of 6 mm is added on both sides of the first core 20.1. This provides a single layer of 6 mm. This reduces the production cycle time required for the optical component 2.

[0070] The first outer layer 21.1 is shown in Figure 5 (It is a three-dimensional image) and Figure 6 In the first non-limiting embodiment (which is a cross-sectional view); and in Figure 12 (It is a three-dimensional image) and Figure 13 In the second non-limiting embodiment (which is a cross-sectional view), it can be noted that... Figure 12 and Figure 13 In the middle, the first outer layer 21.1 has a slope 210.9, which allows for the acquisition of Figure 9 The cutoff area shown is 29.

[0071] exist Figure 6 and Figure 13 It can be noted that, like the first core 20.1, the second core 20.2 has an asymmetrical and complex shape with abrupt changes in thickness.

[0072] In a non-limiting embodiment, step E2 includes injection molding second tabs 200.2 simultaneously with injection molding the first outer layer 21.1, the second tabs extending along a second direction Y on both sides of the first outer layer 21.1. More specifically, the second tabs 200.2 extend along the second direction Y on both sides of the second core 20.2, the second direction being perpendicular to the thickness direction Z of the second core 20.2. The second tabs 200.2 are perpendicular to the first direction X. In a non-limiting embodiment, the second tabs 200.2 are elongated along the second direction Y. In a non-limiting embodiment, the width of the second tabs 200.2 is substantially equal to the thickness of the first core 20.1, as already described with respect to the first tabs 200.1.

[0073] These second tabs 200.2 are substantially parallel to the first tab 200.1.

[0074] Figures 12 to 15 These second convex plates 200.2 are shown.

[0075] Due to the injection molding pressure, the second core 20.2 may rock forward or backward as the material is first injected around it. The second tab 200.2 is configured to prevent the second core 20.2 from pivoting forward or backward. The second tab holds the second core in place during injection molding. Figure 15 The second outer layer 21.2 shown in the figure prevents the second core from moving during injection molding. Specifically, the second tab 200.2 is configured to prevent the second core 20.2 from moving around an axis F-F' that is substantially parallel to the second direction Y during injection molding of the second outer layer 21.2. Figure 12(As shown) rocking. The axis F-F' is substantially parallel to and passes through the second tabs 200.2. Like the first tab 200.1, the second tabs 200.2 are held by the rotary production mold 6 when it is closed, particularly by the fixed and movable portions that close on the second tabs 200.2. Thus, the second tabs 200.2 are clamped (i.e., held) in the rotary production mold 6 and therefore held by it, thereby allowing the second core 20.2, which is arranged in the mold cavity 61 of the rotary production mold 6 but not held in place by the rotary production mold, to be held on both sides but to float in the mold cavity 61.

[0076] Because optical component 2 is elongated in the first direction X, in a non-limiting embodiment, the second tab 200.2 is positioned away from the first tab 200.1. This allows for greater compensation for the risk of wobbling. Throughout this disclosure, "away from" means that the second tab 200.2 is positioned relative to the first tab 200.1 at a distance greater than the size of the first tab 200.1 in the first direction X. In a non-limiting embodiment, if only a single first tab is present on one side of the first core 20.1, the size in the first direction X corresponds to the dimension of the first tab's cross-section in the first direction X as it passes through a plane perpendicular to the second direction Y. In another non-limiting example, if multiple first tabs are present on one side of the first core 20.1, the size in the first direction X corresponds to the distance in the first direction X between the outermost of all the first tabs located on the same side of the core 20.1. The position of the second tab 200.2 depends on the results of structural calculations derived from upstream rheological simulations. This allows for the identification of the correct distance at which the second tab 200.2 is positioned on a given layer to avoid wobbling during overmolding with the second layer. The center of rotation, the deformation amplitude of the insert (core) during overmolding, and thus the assembly of the structural reinforcement with these second tabs 200.2 are identified. In other words, rheological simulations enable the determination of the precise position of the second tab 200.2 with respect to a remote location.

[0077] In one non-limiting embodiment shown, a second tab 200.2 is injection molded on each side of the second core 20.2. Thus, there are two second tabs 200.2, one on one side of the second core 20.2 and the other on the other side of the second core 20.2.

[0078] In another non-limiting embodiment ( Figure 12 In (not shown), multiple second tabs 200.2 are injection molded on each side of the second core 20.2.

[0079] exist Figure 1aIn step E3, shown as F3(21.2, 20.2), the second outer layer 21.2 is injection molded, which encapsulates the second core 20.2. The second core 20.2 and the second outer layer 21.2 are integrally formed. Figure 8 and Figure 15 The third core 20.3 shown in the image forms... Figure 2 and Figure 9 The optical component 2 is shown in the image. It should be noted that the second outer layer 21.2 does not enclose the second protrusion 200.2.

[0080] exist Figure 7 and Figure 14 It can be noted that, like the first core 20.1 and the second core 20.2, the third core 20.3 has an asymmetrical and complex shape.

[0081] According to a non-limiting embodiment, Figure 7 The second outer layer 21.2 shown in the diagram enables the generation of Figure 2 The optical component 2 shown is configured to produce a "flat" beam Fx. This flat beam forms a portion of the near beam, i.e., the flat portion, that is, a portion with a flat cutoff.

[0082] According to the second non-limiting embodiment Figure 14 The second outer layer 21.2 shown in the diagram enables the generation of Figure 9 The optical component 2 shown is configured to generate a "knotted" beam Fx. This knotted beam forms a portion of the near-beam, namely the knotted portion, that is, a portion with a knotted cutoff, particularly the inclined portion.

[0083] Therefore, by means of this production method 1, complex and asymmetrical optical components 2 can be produced with high precision, especially optical components 2 consisting of at least one collimator 26, a reflector 27 and a lens 28.

[0084] Once all the cores 20 and outer layers 21 required for the optical component 2 have been injection molded, proceed with the next steps.

[0085] In a non-limiting embodiment, in Figure 1a In step E4, shown as F4(200.1, 200.2, OFF), the first tab 200.1 and the second tab 200.2 are cut. Thus, all the tabs 200 that have been injection molded and used to hold the core in place are cut. This allows for a reduction in the weight of the optical component 2 and a limitation on its size. It should be noted that if the first tab 200.1 and / or the second tab 200.2 were not cut, they could be used to secure the optical component 2 in place within the light-emitting device 1.

[0086] In a non-limiting embodiment, production method 1 further includes... Figure 1a Step E1', shown as F1'(20.1, 200.1), involves cooling the first core 20.1 and the first tab 200.1, which are injection molded during step E1. This step E1' is performed before step E2.

[0087] In a non-limiting embodiment, production method 1 further includes... Figure 1a Step E2', shown as F1'(21.1, 200.2), involves cooling the first outer layer 21.1 (with a second tab 200.2 where appropriate) that was injection-molded during step E2. This step E2' is performed before step E3.

[0088] In a non-limiting embodiment, production method 1 further includes... Figure 1a Step E3', shown as F3'(21.2), involves cooling the second outer layer 21.2 that was injection molded during step E3.

[0089] Therefore, in a non-limiting embodiment, once the cores 20.1, 20.2 or the outer layers 21.1, 21.2 have been injection molded, they are immediately cooled after and before the injection molding of the other element (core 20.1, 20.2 or outer layer 21.1, 21.2) of the optical component 2. In other words, the steps of cooling the cores 20.1, 20.2 included in production method 1 are as many as those present in the optical component 2 to be produced, and the steps of cooling the outer layers 21.1, 21.2 are as many as those present in the optical component 2 to be produced. It should be noted that the number of cooling stations used for a given layer depends on the thickness of the layer in question, the amount of space occupied in the mold, and the number of available stations.

[0090] It should be noted that steps E1 and E2 can be repeated multiple times as needed to add multiple cores 20 and multiple outer layers 21.

[0091] Therefore, if it is necessary to produce a core with a first core 20.1 and more than two outer layers 21 (such as...), Figure 1b The optical component 2 shown is manufactured using method 1, which includes the following steps, where n is an integer ranging from 2 to N, where N>=3: - The first step E1 (as described above) of F1(20.1, 200.1) involves injection molding a first core 20.1 extending along a first direction X. This first step includes injection molding first tabs 200.1 on both sides of the first core 20.1 along a second direction Y perpendicular to the first direction X. - The 2n-1st step of injection molding the nth tab, which extends on both sides of the nth core 20.n in the second direction Y, the step of injection molding the nth tab forms part of the step of injection molding the (n-1)th outer layer 21.n-1. - The 2nth step of injection molding the nth outer layer 21.n, which encapsulates the nth core 20.n, the nth core 20.n and the nth outer layer 21.n form the (n+1)th core 20.n+1.

[0092] In a non-limiting embodiment, production method 1 further includes... Figure 1b Step E1', shown as F1'(20.1, 200.1), involves cooling the first core 20.1 and the first tab 200.1 that were injection molded during step E1.

[0093] In a non-limiting embodiment, production method 1 further includes... Figure 1b Step E2', shown as F1'(21.n, 200.n), involves cooling the nth outer layer 21.n, on which the nth tab 200.n is injection molded during step E2.

[0094] Repeat steps E2 and E2' until N is reached.

[0095] According to a non-limiting embodiment, for n>=3, the 2n-1th injection molding step is optional. Specifically, the presence of the first tab 200.1 and the second tab 200.2, and particularly when the second tab is located away from the first tab, may be sufficient to ensure the stability of the optical component 2 in the mold, especially when the dimensions of the optical component 2 do not change significantly in the first direction X in subsequent steps. This facilitates the design and production of the mold and the step of cutting the tabs.

[0096] According to a non-limiting embodiment, the nth tab 200.n is located away from the (n-1)th tab 200.n-1.

[0097] According to a non-limiting embodiment, the nth tab 200.n is away from all pth tabs 200.p, where p takes any integer value between 1 and n-1.

[0098] When the optical component is particularly elongated in the X direction, the distance between the tabs allows for greater compensation for the risk of wobbling. In particular, when the optical component 2 elongates significantly during the injection molding step, it is advantageous to arrange new tabs away from the previous tabs at the elongated portion.

[0099] Similar to the description above for the second tab 200.2 and the first tab 200.1, the term "far away" applies to the nth tab 200.n, the (n-1)th tab 200.n-1, and the pth tab 200.p.

[0100] When there is a 2n-1 injection molding step, the above-mentioned distance between the tabs can be applied.

[0101] Once all the cores 20 and outer layers 21 required for the optical component 2 have been injection molded, proceed with the next steps.

[0102] exist Figure 1b In step E3, shown as F3(200.1, 200.n, OFF), the first tab 200.1 and the nth tab 200.n are cut. Thus, all the tabs 200 that have been injection molded and used to hold the core in place are cut. Alternatively, only some of the tabs are cut, particularly to reduce the weight of the optical component 2, and the other tabs are retained for securing the optical component 2 in place within the light-emitting device 1.

[0103] Optical components 2 are produced using a rotary production mold 6 via the aforementioned production method 1. Figure 17 The image shows a rotary production die 6. Rotary production die 6 is also known as rotary die 6 or die 6.

[0104] The mold 6 includes at least two injection molding stations and at least two mold cavities configured to receive the optical component 2 during a corresponding step in the production of the optical component 2. It should be noted that the production step is either the injection molding of the core 20 or the injection molding of the outer layer 21.

[0105] The following description explains how to use a rotary mold 6 to produce an optical component 2, which, in a non-limiting embodiment, comprises: a first core 20.1 having a first tab 200.1; a first outer layer 21.1, which, if appropriate, has a second tab 200.2; and a second outer layer 21.2. In this case, in one non-limiting embodiment shown, the rotary mold 6 includes three injection molding stations 60.1, 60.2, and 60.3 and three mold cavities 61.1, 61.2, and 61.3, respectively. Throughout the rest of the specification, reference numeral 60 generally denotes an injection molding station, reference numeral 61 generally denotes a mold cavity, and reference numeral 62 generally denotes a cooling station.

[0106] Injection molding stations 60.1, 60.2, and 60.3 are fixed, while mold cavities 61.1, 61.2, and 61.3 are movable. In a non-limiting embodiment, they are arranged on a rotating movable plate 600.

[0107] The first injection molding station 60.1 enables the execution of the first step E1, namely, injection molding the first core 20.1 of the optical component 2, which has a first protrusion 200.1. The first core 20.1 is located in the first mold cavity 61.1.

[0108] Then, the plate 600 is rotated to bring the first core 20.1 in front of the second injection molding station 60.2. The second step E2 can then be performed, namely, injection molding the first outer layer 21.1 of the optical component 2 (which may have a second tab 200.2 if appropriate).

[0109] Then, the plate 600 is rotated again to bring the second core 20.2 (formed by the first core 20.1 and the first outer layer 21.1) in front of the third injection molding station 60.3. The third step E3, namely the injection molding of the second outer layer 21.2 of the optical component 2, can then be performed.

[0110] It should be noted that the first tab 200.1 and the second tab 200.2 are held in place by the movable and fixed parts (not shown) of the rotating mold 6.

[0111] The optical component 2 is thus demolded from the rotating mold 6; therefore, the optical component is removed from the third mold cavity 61.3. When the optical component 2 is removed from the rotating mold 6, the first protrusion 200.1 and the second protrusion 200.2 can be cut.

[0112] In a non-limiting embodiment, the rotary mold 6 further includes at least two cooling stations 62.

[0113] In a non-limiting embodiment, the rotary mold 6 further includes as many cooling stations 62.1, 62.2, 62.3, etc., as the existing mold cavities 61.1, 61.2, 61.3, etc. It should be noted that the number of cooling stations used for a given layer depends on the thickness of the layer in question, the amount of space occupied in the mold, and the number of available stations. Figure 17 In the non-limiting example shown, the rotary mold includes three cooling stations 62.1, 62.2 and 62.3.

[0114] Before presenting the optical component 2, which is being produced, to the subsequent injection molding station 60, it is presented to the cooling station 62 for cooling. As can be seen, the mold cavity 61 and the cooling station 62 alternate.

[0115] Therefore, after the first core 20.1 and the first tab 21.1 have been injection molded, in a non-limiting embodiment, the rotary mold 6 is rotated to present them to the first cooling station 62.1. Similarly, after the first outer layer 21.1 and (where appropriate) the second tab 200.2 have been injection molded, in a non-limiting embodiment, the rotary mold 6 is rotated again to present them to the second cooling station 62.2. Finally, after the second outer layer 21.2 has been injection molded, in a non-limiting embodiment, the rotary mold 6 is rotated again to present the optical component 2 to the third cooling station 62.3.

[0116] It should be noted that, for this non-limiting example of the rotary mold 6, three different optical components 2 can be produced simultaneously, with these three different optical components being produced in different production steps and located in different mold cavities 61. Therefore, when the optical component 2 is completed by injection molding the second outer layer 21.2 at the third injection molding station 60.3 (e.g., arranged in the first mold cavity 61.1), the first outer layer 21.1 and (where appropriate) the second tab 200.2 of the second optical component 2 (e.g., arranged in the second mold cavity 61.2) can be injection molded at the second injection molding station 60.2, and injection molding of the first core 20.1 with the first tab 200.1 for the third optical component 2 (e.g., arranged in the third mold cavity 61.3) can begin at the first injection molding station 60.1. This saves the process time required to produce multiple optical components 2. It should be noted that the three optical components 2 in the production process are cooled simultaneously in parallel, rather than one optical component 2 at a time. This saves cooling time in the assembly.

[0117] It should be noted that if an additional core 20 and outer layer 21 are present, the rotary mold 6 may of course include an additional injection molding station 60 and a cooling station 62.

[0118] In a non-limiting embodiment, the demolding axis C-C' of the optical component 2 is perpendicular to the optical axis A-A' of the optical component 2. The demolding axis C-C' corresponds to the axis of demolding from the mold 6. This makes demolding the optical component 2 easier and avoids an excessive number of undercuts. If the demolding axis C-C' of the optical component 2 were parallel to the optical axis A-A', demolding would be too complicated, and there would be too many undercuts due to the complexity of the optical component 2.

[0119] Of course, the description of the present invention is not limited to the above embodiments and the above-described field. Therefore, in another non-limiting embodiment, two injection channels 25.1 may be provided, arranged on each side of the first core 20.1 and between two first protrusions 200.1 arranged on each side of the first core 20.1, as shown below. Figure 7 or Figure 14 What is shown.

[0120] Therefore, the described invention has the following particular advantages: - It can produce optical components with complex and asymmetrical shapes. - It can produce optical components with considerable thickness. - Core misalignment can be prevented during the encapsulation of core 20 by outer layer 21, thus avoiding optical components having different shapes and dimensions than originally intended. This better conforms to the originally intended shape. It should be noted that if the core misaligns, optical component 2 will no longer have the desired shape, and this will affect the beam produced by optical component 2.

[0121] - Prevent the overmolded core 20 from shaking, because when the material relaxes, it can cause deformation ranging from warping and cracking to rupture, depending on the amplitude of the shaking. - During injection molding, even in cases of material flow imbalance caused by asymmetrical shapes, compliant optical components 2 can be achieved. - By means of the first tab 200.1 and the second tab 200.2, asymmetrical and complex parts can be produced compared to symmetrical, uncomplex parts that will also be made using cores and layers that enclose each other.

Claims

1. A method (1) for manufacturing an optical component (2), characterized in that, The production method (1) includes: - The first step of injection molding the first core (20.1), the first core (20.1) extending along a first direction (X), - A second step of injection molding a first outer layer (21.1), wherein the first outer layer encapsulates the first core (20.1), and the first core (20.1) and the first outer layer (21.1) form a second core (20.2), characterized in that the first step of injection molding the first core (20.1) includes injection molding a first tab (200.1) on both sides of the first core (20.1) along a second direction (Y) perpendicular to the first direction (X).

2. The production method (1) as described in claim 1, wherein, The first tab (200.1) is elongated along the second direction (Y).

3. The production method (1) as described in claim 1 or 2, wherein, The first tab (200.1) has an elongated shape in a cross section passing through a plane perpendicular to the second direction (Y).

4. The production method (1) as described in any of the preceding claims, wherein, At least two first tabs (200.1) are injection molded on at least one side of the first core (20.1).

5. The production method (1) as described in the preceding claim, wherein, The second step of injection molding the first outer layer (21.1) is performed by means of a material injection channel (25.1) arranged between the at least two first tabs (200.1).

6. The production method (1) as described in any of the preceding claims, wherein, The production method (1) further includes the following steps: Where n is an integer ranging from 2 to N, where N>=3: - The 2n-1st step of injection molding the nth tab, the nth tab extending on both sides of the nth core (20.n) in the second direction (Y), the step of injection molding the nth tab forms part of the step of injection molding the (n-1)th outer layer (21.n-1), the 2n-1st injection molding step is optional for n>=3; - The 2nth step of injection molding the nth outer layer (21.n), wherein the nth outer layer encapsulates the nth core (20.n), and the nth core (20.n) and the nth outer layer (21.n) form the (n+1)th core (20.n+1).

7. The production method (1) as described in any of the preceding claims, wherein, The production method (1) further includes the step of cutting the first protrusion (200.1).

8. The production method (1) as described in claims 6 and 7, wherein, The production method (1) further includes the step of cutting the nth tab (200.n) or some of the tabs in the nth tab (200.n).

9. The production method (1) according to any one of claims 6 to 8, wherein, The nth convex piece (200.n) is far away from the (n-1)th convex piece (200.n-1).

10. The production method (1) as described in any of the preceding claims, wherein, The optical component (2) includes a light incident area (26) configured to face the light source (40), and the optical component includes a light exit area (24).

11. A light-emitting device (4) for a vehicle (3), the light-emitting device (4) comprising an optical component (2) manufactured by the production method (1) as described in any of the preceding claims, and at least one light source (40).

12. The light-emitting device (4) as claimed in the preceding claim, wherein, The light-emitting device (4) is a headlight, a taillight, or an interior lighting device.

13. A rotary production mold (6) for an optical component (2), characterized in that, The rotary mold (6) includes at least two injection molding stations (60) and at least two mold cavities (61), the at least two mold cavities being configured to receive the optical component (2) during a corresponding step in the production of the optical component (2), a first injection molding station (60.1) being configured to perform a first injection molding step of the production method (1) as described in any one of claims 1 to 10, and a second injection molding station (60.2) being configured to perform a second injection molding step of the production method (1) as described in any one of claims 1 to 10.

14. The rotary mold (6) as described in claim 13, wherein, The rotary mold (6) includes three injection molding stations (60) and optionally at least two additional cooling stations (62).

15. The rotary mold (6) as claimed in claim 13 or claim 14, wherein, The rotating mold (6) includes a demolding axis (C-C') that is perpendicular to the optical axis (A-A') of the optical component (2).

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