Lens and overmold method of manufacture

Inventors: Nicholas Brett Jarrett (Saint Bonifacius, MN); Chunmei Kang (Plymouth, MN); Darin Wampler (Prior Lake, MN); David William Franke (Golden Valley, MN); Ryan Van Domelen (Saint Paul, MN)

Assignee: Banner Engineering Corp.

G02B1/041 B29D11/00403 G02B2003/0093

View Patent ↗

Loading inventors, assignments & file history…

Monitor This Case

Get email alerts when status or documents change.

Order Certified Copies

Most orders are placed with the USPTO same day — all within 24 business hours.

Order via The Patent Place →

Pre-filled with this patent's details

Quick Facts

Patent No.: US 12687657
App. No.: 18/381,025
Granted: Jul 21, 2026
Kind: B2

External Links

USPTO Patent Center↗ Full Patent PDF↗

Abstract

Some embodiments of the technology disclosed herein relate to a lens assembly including a lens base and a lens fill. The less base is constructed of a first material and defines a lens interior surface and a plurality of ribs extending axially from the lens interior surface. The plurality of ribs define a plurality of cavities between the plurality of ribs. The lens fill is constructed of a second material and is located within the plurality of cavities. The first material includes a plastic and the second material includes a plastic.

Claims (27)

1 . A lens assembly comprising:

a lens base constructed of a first material, wherein the lens base defines a lens interior surface and a plurality of ribs extending axially from the lens interior surface, wherein the plurality of ribs define a plurality of cavities between the plurality of ribs, wherein the lens base comprises a convex lens and a flange extending laterally from the convex lens, wherein the convex lens is configured to transmit less than or equal to 120 GHz electromagnetic waves; and

a lens fill constructed of a second material, wherein the lens fill is located within the plurality of cavities,

wherein the first material comprises a plastic and the second material comprises a plastic.

2 . The lens assembly of claim 1 , wherein the first material defines a first color and the second material defines a second color that is different from the first color.

3 . The lens assembly of claim 1 , wherein the lens base defines a lens thickness greater than or equal to 3 millimeters (mm) and less than or equal to 50 mm.

4 . The lens assembly of claim 3 , wherein each of the plurality of ribs defines a rib length, and wherein the rib length is less than or equal to the lens thickness.

5 . The lens assembly of claim 1 , wherein the lens base defines a lens base wall thickness defined by the lens interior surface and a lens exterior surface, and wherein the lens base wall thickness is less than or equal to 5 mm.

6 . The lens assembly of claim 5 , wherein each of the plurality of ribs defines a rib thickness, and wherein the rib thickness is at least 25% of the lens base wall thickness.

7 . The lens assembly of claim 1 , wherein each of the plurality of ribs tapers from a rib first end proximate to the lens interior surface to a rib second end distal from the lens interior surface.

8 . The lens assembly of claim 1 , wherein the lens base further comprises a flange, and wherein the flange defines at least one window.

9 . A method of making a lens comprising:

molding a lens base having a lens interior surface and a plurality of ribs extending axially from the lens interior surface using a first material, wherein the plurality of ribs define a plurality of cavities between the plurality of ribs, wherein molding the lens base comprises molding a convex lens and a flange extending laterally from the convex lens, wherein the lens is configured to transmit less than or equal to 120 GHz electromagnetic waves; and

molding a lens fill within the plurality of cavities using a second material.

10 . The method of claim 9 , wherein the first material defines a first color and the second material defines a second color that is different from the first color.

11 . The method of claim 9 , wherein molding the lens base defines a lens thickness, and wherein the lens thickness is greater than or equal to 3 millimeters (mm) and less than or equal to 50 mm.

12 . The method of claim 11 , wherein each of the plurality of ribs defines a rib length, and wherein the rib length is less than or equal to the lens thickness.

13 . The method of claim 9 , wherein molding the lens base defines a lens base wall thickness defined by the lens interior surface and a lens exterior surface, and wherein the lens base wall thickness is less than or equal to 5 mm.

14 . The method of claim 13 , wherein each of the plurality of ribs defines a rib thickness, and wherein the rib thickness is at least 25% of the lens base wall thickness.

15 . The method of claim 9 , wherein each of the plurality of ribs tapers from a rib first end proximate to the lens interior surface to a rib second end distal from the lens interior surface.

16 . A radar lens system comprising:

a lens base constructed of a first material, wherein the lens base comprises a convex lens and a flange extending laterally from the convex lens, wherein the convex lens defines a lens interior surface and a plurality of ribs extending axially from the lens interior surface, and wherein the plurality of ribs define a plurality of cavities between the plurality of ribs; and

a lens fill constructed of a second material, wherein the lens fill is located within the plurality of cavities, and,

wherein the flange defines at least one window and the lens fill extends across the at least one window.

17 . The radar lens system of claim 16 , wherein the first material comprises a plastic and the second material comprises a plastic.

18 . The radar lens system of claim 16 , further comprising a radar sensor located proximate a center of a base of the convex lens.

19 . The radar lens system of claim 16 , further comprising a light emitting diode (LED) located proximate the at least one window, wherein the lens fill transmits light therethrough.