Method of rapid insert backing

Abstract

Manufacturing a reflex insert tool includes the steps of assembling optical pins in a bundle, and inserting same into a mold clamp assembly. The mold clamp assembly is placed into a vat, wherein an electroformed skin is developed which in turn is removed from the bath. A cold spraying technique is utilized applying a build up of material on the back surface of the electroformed skin. The back surface of the reflex insert is then machined and through wire EDM, configured to a desired shape and thereafter ready for insertion into a tool for injection molding plastic parts therefrom.

1 . A method of manufacturing a reflex insert tool for use in manufacturing an optical lens, the method comprising the steps of:
 providing a plurality of machined optical pins and a clamp for securing said pins;   organizing each of said optical pins into an arrangement;   inserting and securing the arranged optical pins into said clamp;   placing the clamp into a tank filled with electroformable material for a period of time long enough to create an electroformed skin;   removing the clamp from the tank;   separating the electroformed skin from the clamp;   applying backing material via a cold process to a side of the electroformed skin to create thickened reflex insert; and   machining the thickened reflex insert to predetermined final dimension.   
   
   
       2 . The method of manufacturing a reflex insert tool for use in manufacturing an optical lens as claimed in  claim 1 , wherein the step of applying backing material includes a cold spray process. 
   
   
       3 . The method of manufacturing a reflex insert tool for use in manufacturing an optical lens as claimed in  claim 1 , wherein the step of applying backing material includes a low pressure non-electroforming process. 
   
   
       4 . The method of manufacturing a reflex insert tool for use in manufacturing an optical lens as claimed in  claim 1 , wherein the step of applying backing material includes selectively delivering patterns of material from the group consisting of aluminum and/or zinc, to an underside surface of the electroformed skin. 
   
   
       5 . The method of manufacturing a reflex insert tool for use in manufacturing an optical lens as claimed in  claim 1 , wherein the machining step includes using wire EDM to create a profile of the insert tool. 
   
   
       6 . The method of manufacturing a reflex insert tool for use in manufacturing an optical lens as claimed in  claim 1 , wherein the machining step includes removing material from a back side of the thickened reflex insert to a desired thickness, and cutting a desired profile to create a finished insert tool. 
   
   
       7 . The method of manufacturing a reflex insert tool for use in manufacturing an optical lens as claimed in  claim 1 , wherein the step of placing the clamp into a tank filled with electroformable material, includes building up an electroformed skin having a thickness of about 0.140 of an inch. 
   
   
       8 . A method of manufacturing a reflex insert tool comprising the steps of:
 providing reflex pins and a mandrel for securing said pins, each said pin having a prism;   arranging said pins in the mandrel and securing the mandrel;   locating the mandrel into a tank filled with electroformable material;   creating an electroformed skin having an impression of said prism;   removing the mandrel and the electroformed skin from the tank;   separating the electroformed skin from the mandrel;   applying backing material to the electroformed skin using non-electroforming methods; and   machining the electroformed skin to create a finished insert tool.   
   
   
       9 . The method of manufacturing as claimed in  claim 8 , wherein the mandrel is a multi-piece configuration that is operable to receive a plurality of optical pins and maintain the pins in place during an electroforming process. 
   
   
       10 . The method of manufacturing as claimed in  claim 8 , wherein the step of creating an electroformed skin includes electroforming layers of material on top of the prisms to create a skin layer having a prism side and a rough side. 
   
   
       11 . The method of manufacturing as claimed in  claim 8 , wherein the step of creating an electroformed skin lasts for a period of less than two weeks. 
   
   
       12 . The method of manufacturing as claimed in  claim 8 , wherein the step of applying backing material includes spraying metal onto an underside of the electroformed skin. 
   
   
       13 . The method of manufacturing as claimed in  claim 8 , wherein the step of applying backing material to the electroformed skin take less than one week to complete. 
   
   
       14 . The method of manufacturing as claimed in  claim 8 , wherein the step of machining the electroformed skin includes removing material from a back side of the skin so as to create a uniformly thick portion. 
   
   
       15 . The method of manufacturing as claimed in  claim 8 , wherein the step of machining the electroformed skin includes cutting the skin into a desired profile to resemble the profile of a lens. 
   
   
       16 . The method of manufacturing as claimed in  claim 8 , wherein the step of applying backing material takes less than a few days to complete. 
   
   
       17 . The method of manufacturing as claimed in  claim 8 , wherein the electroformed skin has a first density, and the backing material has a lesser density. 
   
   
       18 . A reflex insert tool comprised of:
 a first prism portion having a configuration of a plurality of optical pins;   a second portion being comprised of a metal layer from the group consisting of cobalt or nickel, said second portion developed by an electroforming process; and   a third portion being comprised of a layer of metal that is substantially thicker than the second portion, said third portion is developed from a cold delivery process.   
   
   
       19 . The reflex insert tool as claimed in  claim 18 , wherein the third portion has been machined to a predetermined thickness of approximately 0.50 inches thick. 
   
   
       20 . The reflex insert tool as claimed in  claim 18 , wherein a density of the second portion is greater than the density of the third portion.