Abstract: The multistep injection molding device is for manufacturing thick lenses for use with an illumination apparatus. The injection molding device includes two sets of mold core inserts forming mold cavities when the injection molding device is in a closed position. The lens core part is formed in a first injection shot station. The molded lens core part is then moved to a post-molding cooling station in which it is further cooled inside a corresponding mold cavity. Two outer lens parts are formed sequentially over the lens core part in second and third injection shot stations. A method of manufacturing a thick lens is also disclosed.

Abstract: The injection molding apparatus is provided for making highly accurate optical parts having structured reflective or deflecting optical surfaces. The apparatus includes a removable mold insert made of two or more mold insert segments. The mold insert segments are juxtaposed at mating lateral planar surfaces to form a reversed structured surface. The mold insert segments also includes a gas venting circuit having conduits formed when the mold insert segments are juxtaposed. A cooling circuit is provided in the mold insert segments.

Abstract: The lens is made by injection molding in a mold through the injection of molten plastic material in at least three injection shots using a multistep process. It includes a first outer lens part, a second outer lens part and a lens core part forming an interior of the lens. The lens core part is embedded between the first and second outer lens parts. The lens core part is divided into at least two subparts separated at least partially by at least one elongated slot extending across the lens core part between the first and second surfaces of the lens core part. The slot or slots made through the lens core part are filled and fused with the plastic material of the first outer lens part.

Abstract: The lens is made by injection molding in a mold through the injection of molten plastic material in at least three injection shots using a multistep process. It includes a first outer lens part, a second outer lens part and a lens core part forming an interior of the lens. The lens core part is embedded between the first and second outer lens parts. The lens core part is divided into at least two subparts separated at least partially by at least one elongated slot extending across the lens core part between the first and second surfaces of the lens core part. The slot or slots made through the lens core part are filled and fused with the plastic material of the first outer lens part.

Abstract: The multistep injection molding device is for manufacturing thick lenses for use with an illumination apparatus. The injection molding device includes two sets of mold core inserts forming mold cavities when the injection molding device is in a closed position. The lens core part is formed in a first injection shot station. The molded lens core part is then moved to a post-molding cooling station in which it is further cooled inside a corresponding mold cavity. Two outer lens parts are formed sequentially over the lens core part in second and third injection shot stations. A method of manufacturing a thick lens is also disclosed.

Abstract: The injection molding apparatus is provided for making highly accurate optical parts having structured reflective or deflecting optical surfaces. The apparatus includes a removable mold insert made of two or more mold insert segments. The mold insert segments are juxtaposed at mating lateral planar surfaces to form a reversed structured surface. The mold insert segments also includes a gas venting circuit having conduits formed when the mold insert segments are juxtaposed. A cooling circuit is provided in the mold insert segments.

Abstract: The high sag thick lens is for use in an illumination apparatus, such as a solid state light source. The lens is made of a first lens part having an optical active surface and a series of elongated baffles, the baffles having a top portion, the top portions defining a line that follows the curvature of the optical active surface to create a second lens part of uniform thickness. A second lens part is fused to the first lens part to create the lens. The second lens part has an optical active surface and a series of elongated baffles, the baffles having a thickness comparable to the thickness of the corresponding optical active surfaces. The first and the second baffles are intertwined along the entire length of their lateral surfaces.

Abstract: The lens array assembly includes a lens array support made of a first molded plastic material exhibiting a volumetric shrinkage upon cooling, the lens array support having a plurality of spaced-apart apertures; and an array of lenses made of second molded plastic material exhibiting a volumetric shrinkage upon cooling, each lens corresponding to one of the apertures of the lens array support and having an actual position in the lens array support that is within a maximum tolerance of 0.20 mm compared to each lens design position.

Abstract: A moulding process to manufacture a moulded piece having multiple individual optical elements with the same or different dimensions. This is achieved by using a multicolour injection process as well as a multidrop injection manifold. In the first step, the optical elements are moulded without any junction between them. In the second step, a layer of plastic is moulded in order to join together all the optical elements to create a single piece. The moulded piece thus consists of two plastic injections with optical elements which is more easily adaptable to a variety of different designs for lights having two or more colors. New styles of optical elements, along with varied and original geometric arrangements can thus be imagined. Furthermore, signaling functions having by their regulations different colors can heretofore be placed within a same zone of glass.

Abstract: An injection process for forming a retroreflector on a matrix mold having a plurality of prisms that each define a cavity. The process includes the steps of a) injecting a first layer of plastic on the matrix mold for partially filling up each prism up to a predetermined uniform thickness so as to define a recessed portion corresponding with each cavity of the prisms; and b) injecting a second layer of plastic onto of the first layer, the second layer filling up the recessed portion defined in each cavity of the prisms so that second layer defines a flat portion on an exterior side of the second layer.

Abstract: A moulding process to manufacture a moulded piece having multiple individual optical elements with the same or different dimensions. This is achieved by using a multicolour injection process as well as a multidrop injection manifold. In the first step, the optical elements are moulded without any junction between them. In the second step, a layer of plastic is moulded in order to join together all the optical elements to create a single piece. The moulded piece thus consists of two plastic injections with optical elements which is more easily adaptable to a variety of different designs for lights having two or more colours. New styles of optical elements, along with varied and original geometric arrangements can thus be imagined. Furthermore, signalling functions having by their regulations different colours can heretofore be placed within a same zone of glass.

Abstract: An injection process for forming a retroreflector on a matrix mold having a plurality of prisms that each define a cavity. The process includes the steps of a) injecting a first layer of plastic on the matrix mold for partially filling up each prism up to a predetermined uniform thickness so as to define a recessed portion corresponding with each cavity of the prisms; and b) injecting a second layer of plastic onto of the first layer, the second layer filling up the recessed portion defined in each cavity of the prisms so that second layer defines a flat portion on an exterior side of the second layer.

Abstract: Mold pins for use in a mold matrix, as used in the production of electroforms, are provided with means to alter the longitudinal axis of the pins relative to that of adjacent pins so that the longitudinal axis of the pins are tapered with respect to one another towards the operative ends of the pins. In one embodiment of the invention a dowel is inserted into a sidewall of the pin and extends normal thereto to space the pin from an adjacent one. In another embodiment, a spacing member of a desired thickness is applied to the shank of the pin at a location remote from the operative end thereof.