US 12,379,564 B2
Method of manufacturing lens and light emitting device
Tsuyoshi Okahisa, Tokushima (JP); Toshiyuki Fujii, Anan (JP); and Tomohisa Kishimoto, Anan (JP)
Assigned to NICHIA CORPORATION, Anan (JP)
Filed by NICHIA CORPORATION, Anan (JP)
Filed on Nov. 9, 2022, as Appl. No. 17/984,202.
Application 17/984,202 is a division of application No. 16/558,276, filed on Sep. 2, 2019, granted, now 11,644,635.
Claims priority of application No. 2018-162679 (JP), filed on Aug. 31, 2018.
Prior Publication US 2023/0076561 A1, Mar. 9, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. G02B 7/02 (2021.01); B29D 11/00 (2006.01); G02B 7/00 (2021.01); H10H 20/855 (2025.01); H10H 20/01 (2025.01); H10H 20/85 (2025.01)
CPC G02B 7/02 (2013.01) [B29D 11/00269 (2013.01); G02B 7/003 (2013.01); H10H 20/855 (2025.01); H10H 20/034 (2025.01); H10H 20/8506 (2025.01)] 10 Claims
OG exemplary drawing
 
1. A method of manufacturing a lens, the method comprising:
forming a cover blank, the forming a cover blank comprising, injecting a thermosetting first resin in a first mold and curing the thermosetting first resin, to form a cover blank having a plurality of cover parts,
each of the cover parts including a lens part having a plurality of lateral sides, a connection part constituting a plurality of lateral side walls each extending downward from a respective one of the plurality of lateral sides of the lens part, and a plurality of flange parts each extending outward from a lower-end portion of a corresponding one of the plurality of lateral side walls,
the lens part and the connection part defining a recess having an opening facing downward, the lens part defining a bottom surface of the recess and the plurality of lateral side walls defining lateral surfaces of the recess, which define the opening of the recess, the recess being formed inward of the plurality of flange parts, and
the lens part, the plurality of flange parts, and the connection part being continuous to one another;
removing a part or all parts of the first mold;
arranging the cover blank in a second mold;
forming a lens blank, the forming a lens blank comprising, injecting a thermosetting second resin having a greater light absorptance or a greater light reflectance than the thermosetting first resin into the second mold and curing the thermosetting second resin, to form a lens blank having a light-shielding part between adjacent ones of the cover parts; and
obtaining individual lenses, the obtaining individual lenses comprising, taking out the lens blank from the second mold, and cutting the lens blank at the light-shielding part located between adjacent ones of the cover parts to obtain individual lenses each with a plurality of lateral end surfaces and an upper surface of each of the plurality of flange parts and the plurality of lateral side walls covered by the light-shielding part.