Patent ID: 7197218

Claim:
An integrated linear array of injection molded light-conductive pipes, each pipe comprising an input optical face and an output optical face connected by an elongated body of light-conductive material, where the pipes in the linear array are connected by integral alignment features projecting from the elongated bodies of the molded light-conductive pipes and are formed by: a.) forming a light pipe mold that includes multiple elongated cavities, each having two optical end faces, openings for injecting molten material into the cavities distant from either optical end face, and cavity contours that form at least one integral light pipe alignment feature projecting from the elongated bodies of the light pipes, wherein the openings for injecting molten material into the cavities are located in the alignment feature cavity contours; b.) providing molten material from a supply of molten material; c.) injecting the molten material through the openings; and d.) cooling and solidifying the molten material to form an array of light pipes connected by alignment features, each light pipe in the array having an input optical face and an output optical face connected by an elongated body of light-conductive material.