Method for manufacturing a lens element

Abstract

The invention relates to a method for producing an optical lens element, in particular for illumination purposes, in particular a method for producing a headlamp lens for a headlamp, in particular for an automobile headlamp (10), wherein a preform lens element (42, 43) is injection molded by means of at least one mold from a transparent plastic which is liquefied by heating, wherein the preform lens element (42, 43) is cooled such that the plastic solidifies, and wherein at least one optically effective surface of the preform lens element (42, 43) is subsequently heated such that the plastic is plasticizable on the optically effective surface, in particular up to a maximum of 1000 micrometers, wherein the preform lens element (42, 43) with the optically effective surface is pressed into the lens element in a final contour mold.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing (optical) lens elements, particularly for lighting purposes, and more particularly to a method for manufacturing headlight lenses for vehicle headlights, especially for automobile headlights. Background Technology

[0002] DE 10 2007 037 204 A1 discloses a method for manufacturing optical lens elements, particularly for lighting purposes, and in particular a method for manufacturing headlight lenses for vehicle headlights, especially automotive headlights, wherein a preform is formed in an injection mold from a transparent, particularly thermoplastic, particularly generally liquid plastic, particularly by means of an injection molding process, and wherein the preform is subsequently pressed into a lens element, particularly a blank, by means of a final contour mold. WO2014 / 161014 A1, WO 2019 / 179571 A1 and US 10,183,429 B2 (the entire contents of which are incorporated herein by reference) disclose a method for manufacturing injection molded parts, particularly optical elements, wherein injection molding materials are poured at at least two injection stations by means of at least two injection processes, wherein between these at least two injection processes, a preform formed in one of these at least two injection processes is cooled at a cooling station. Summary of the Invention

[0003] The object of the present invention is particularly to provide a headlight lens (mainly) made of plastic that is particularly suitable for matrix headlights or matrix lamps or adaptive high beams, or an optical lens element (mainly) made of plastic. Examples of matrix headlights or adaptive high beams can be found at the following web pages: web.archive.org / web / 20150109234745 / , http: / / www.audi.de / content / de / brand / de / vorsprung_durch_technik / content / 013 / 08 / Audi-A8-erstrahlt-in-neuem-Licht.html (accessed September 5, 2019), www.all-electrocs.de / matrix-led-und-laserlicht-bietet-viele-vorteile / (accessed September 2, 2019), and www.next-mobility.news / led-im-fahrzeug-die-rolle-der-matrixscheinwerfer-und-was-sie-leisten-a-756004 / (accessed September 2, 2019). The goal is to reduce the cost of manufacturing the aforementioned lens elements, particularly for lighting purposes, especially for vehicle headlights, on an industrial scale. "Suitable for industrial scale" specifically refers to establishing a process that allows for the sequential manufacture of thousands of lens elements with low scrap rates without violating specified quality standards or tolerances. This applies particularly to both geometry and optical characteristics. Therefore, headlight lenses have stringent design standards in terms of optical characteristics or optical technical reference values. This is especially true for the cut-off line, as exemplified on page 1040 of the Bosch Automotive Engineering Handbook, 9th edition, ISBN 978-1-119-03294-6. Important optical technical reference values ​​include the cut-off line gradient G and the glare value HV of the headlights of vehicles equipped with headlight lenses. An example of all the optical technical values ​​that need to be followed is disclosed, for instance, in the Bosch Automotive Engineering Handbook, 9th edition, ISBN 978-1-119-03294-6, page 1040. Even higher quality requirements are placed on optical lens elements used in adaptive headlights or matrix headlights. Therefore, it is necessary, for example, to manufacture thousands of lenses while adhering to comparable optical technical characteristics and with a low scrap rate. A low scrap rate specifically refers to a scrap rate of no more than 10%, particularly no more than 5%, and advantageously no more than 2%.

[0004] This invention relates primarily to a method for manufacturing optical lens elements, particularly for lighting purposes, especially for vehicle headlights, and particularly for automotive headlight lenses. The method involves injection molding a pre-formed lens element from a transparent, particularly amorphous, plastic or polymer liquefied by heating or heating, using at least one mold or a (second) injection mold. The pre-formed lens element is cooled to solidify the plastic, and at least one optically effective surface of the pre-formed lens element is subsequently heated such that the plastic is malleable on that surface, with a malleable depth not exceeding 1000 micrometers, particularly not exceeding 500 micrometers, particularly not exceeding 100 micrometers. The pre-formed lens element having the optically effective surface is then pressed into a lens element in a final contour mold.

[0005] The solution of the present invention to achieve the above-mentioned objective is, for example, a method for manufacturing an optical lens element, particularly for lighting purposes, especially for manufacturing headlight lenses for vehicle headlights, particularly for automobile headlights, wherein a pre-formed lens element is injection molded from a transparent plastic liquefied by heating using at least one mold, wherein the pre-formed lens element is cooled such that the plastic solidifies, and wherein at least one surface of the pre-formed lens element that serves as an optically effective surface is subsequently heated such that the plastic is plasticized on the surface that serves as an optically effective surface, wherein the plasticized depth is particularly not more than 1000 micrometers, particularly not more than 500 micrometers, particularly not more than 100 micrometers, wherein the pre-formed lens element is pressed into a lens element having an optically effective surface in a final contour mold.

[0006] In another embodiment of the invention, a pre-molded injection molded plastic (a transparent plastic liquefied by heating) is injection molded into a pre-molded part by means of a first injection mold, the pre-molded part comprising at least one pre-molded body and at least one first gate connected to the pre-molded body, wherein the pre-molded body is subsequently cooled outside the first injection mold, and wherein the pre-molded part is subsequently injected and / or injection molded into an injection molded part in a second injection mold, the injection molded part comprising at least a pre-molded lens element and optionally at least one second gate or an integral gate formed by the first gate and the second gate.

[0007] The solution of the present invention to achieve the above-mentioned objective is, for example, a method for manufacturing an optical lens element, particularly for lighting purposes, especially for vehicle headlights, and particularly for headlight lenses for automobile headlights, wherein injection molding plastic (a transparent plastic liquefied by heating) is injection molded into a pre-molded body and / or pre-molded part by means of a first injection mold, the pre-molded part comprising at least one pre-molded body and at least one first gate connected to the pre-molded body, wherein the pre-molded body and / or pre-molded part is subsequently cooled outside the first injection mold (directly or indirectly, i.e., after one or more intermediate steps), and wherein subsequently... In a second injection mold, a pre-formed injection body is at least partially encapsulated and / or injection molded into a pre-formed lens element by means of other injection plastic (a transparent plastic liquefied by heating), wherein the pre-formed lens element is cooled such that the plastic (particularly completely) solidifies, and wherein at least one surface of the pre-formed lens element designated as an optically effective surface is subsequently heated such that the plastic is plasticized on the surface designated as an optically effective surface, with a plasticity depth particularly not exceeding 1000 micrometers, particularly not exceeding 500 micrometers, particularly not exceeding 100 micrometers, wherein the pre-formed lens element is pressed into a lens element having an optically effective surface in a final contour mold. In this disclosure, the plastic is considered solidified when the temperature of the plastic is below its TG (transition temperature). In this disclosure, the plastic is considered completely solidified when the temperature of the corresponding element made of the plastic is completely below its TG (transition temperature).

[0008] In one technical solution, when a preformed lens element is pressed into a lens element having an optically effective surface in a final contour mold, at least 90%, for example, at least 95%, of the temperature of the preformed lens element is below the TG (transition temperature) of the plastic.

[0009] Heating of the preformed lens element that causes a localized temperature rise above TG (transition temperature or softening temperature) on its surface can be implemented externally or internally in the tool, specifically the final contour mold. Heat can be transferred to the preformed lens element by conduction, convection, and / or radiation. For example, the preformed lens element can be exposed to thermal radiation, such as infrared radiation from an infrared radiator, or thermal radiation generated by an inductive thermal radiator. Subsequently, pressing or embossing is performed in the final contour mold.

[0010] However, as a supplement or alternative, heating can also be carried out in or by means of the final contour mold. Different parts of the final contour mold can have different temperatures. Heating of the conductive or preformed lens element can be carried out through conduction through the lower mold, while heating of the upper surface of the preformed lens element can be carried out through convection and / or thermal radiation (but may also be carried out through conduction).

[0011] During heat transfer via convection, the heated mold or final contour mold, or the molded part of the final contour mold, remains in place with a small imprint stroke, i.e., a small gap from the preformed lens element, until the edge layer temperature (surface temperature) is higher than TG. It is then lifted.

[0012] However, so-called active elements, such as ceramic radiators, can also be placed in the final contour mold, which are also used for edge layer forming after the imprinting stroke. Planar active elements for temperature control can also be provided. Therefore, for example, contour-matched resistance heating elements can be provided, such as milled copper inserts, which are thermally insulated from the rest of the mold, for example, by paint. However, accessible mold coatings can also be used as resistance heating elements. Heating channels can also be provided in the mold. In one embodiment of the invention, the final contour mold is a closed final contour cooling mold in which the preformed lens element is cooled. In another embodiment, the final contour cooling mold has at least two locked molding parts, or the final contour mold has at least one lower mold and at least one upper mold, wherein the weight of the upper mold creates pressure, thereby forming the lens element from the preformed lens element. In another embodiment, the final contour cooling mold has a preset temperature. In a further advantageous embodiment of the invention, the final contour cooling mold is part of the injection mold and is removed together with the preformed lens element from the injection molding machine used for final injection molding.

[0013] In another embodiment of the invention, the optical lens element comprises an optically effective lens body and an optically ineffective edge, wherein the second gate is directly connected to the optical lens body (and advantageously not indirectly via the optically ineffective edge). In a further advantageous embodiment of the invention, the second gate extends at least partially along the first gate, wherein the first and second gates are produced in different steps and advantageously form a common gate (= integral gate) after solidification. The first gate, in particular, forms the dividing wall of the cavity for the second gate.

[0014] In another embodiment of the present invention, the pre-molded part includes at least one second pre-molded body, wherein at least a first gate connects the first pre-molded body and the second pre-molded body together. In a further advantageous embodiment of the present invention, the injection molded part includes at least one second optical lens element, wherein at least a second gate and / or an integral gate connects the first optical pre-molded lens element and the second optical pre-molded lens element together.

[0015] In another embodiment of the invention, the optically ineffective edge is formed only during injection molding. In another embodiment of the invention, the injection molded part is held only on the second gate or the integral gate during cooling. In another embodiment of the invention, the majority of the second gate extends along the first gate. In another embodiment of the invention, the pre-molded part is selectively cooled at a first cooling station or a second cooling station. In another embodiment of the invention, the volume of the first gate accounts for at least 30% of the pre-molded part. In another embodiment of the invention, the volume of the second gate accounts for at least 30% of the injection molded part. In another embodiment of the invention, the cross-sectional area of ​​the first gate is at least 25 mm². 2 Or at least 40 mm 2 In another embodiment of the present invention, the cross-sectional area of ​​the second gate is at least 25 mm². 2 Or at least 40 mm 2 In another embodiment of the present invention, the first optical (automotive) lens element is separated from the integral gate. In another embodiment of the present invention, the at least second optical pre-formed lens element is separated from the integral gate. In another embodiment of the present invention, at least 8 pre-formed lens elements and / or at least 16 pre-formed injection molded bodies are pressed in one pressing step.

[0016] In another embodiment of the invention, in one pressing step, at least eight injection molded parts and / or at least eight pre-molded injection molded parts are pressed, including one gate and at least two pre-molded bodies. In another embodiment of the invention, in one pressing step, at least 16 injection molded parts and / or at least 16 pre-molded injection molded parts are pressed, including one gate and at least two pre-molded lens blanks or pre-molded bodies. In another embodiment of the invention, the pressing device includes at least one hot channel. Advantageously, the cross-sectional area of ​​the hot channel or the majority of the hot channel is not less than 25 mm². 2 Advantageously not less than 40 mm 2 In this disclosure, the cross-sectional area of ​​the hot channel specifically refers to the cross-sectional area orthogonal to the longitudinal direction of the hot channel or orthogonal to the flow direction / average flow direction of the liquid plastic in the hot channel. For example, at least two hot channels may be provided, namely a first hot channel and at least one second hot channel. The first hot channel of the first injection mold may correspond to the second hot channel of the second injection mold, or supply or fill the injection mold with liquid plastic. In another embodiment of the invention, the pre-molded part or pre-molded lens element remains in the tool (synonymous with the injection mold) or closing tool for 130 to 180 seconds, or no more than 180 seconds. In yet another embodiment of the invention, this includes both the injection time and the re-pressing time.

[0017] Advantageously, injection molding is performed at a pressure of not less than 600 bar, particularly not less than 800 bar. Advantageously, injection molding is performed at a pressure not exceeding 1000 bar. Advantageously, injection molding is performed at a pressure between 800 bar and 1000 bar.

[0018] The pressing pressure used to press the mold or sub-mold of the final contour mold against each other is particularly not greater than 1000 bar. The pressing pressure used to press the lens element from the pre-made lens element by means of the final contour mold may not exceed 10 bar.

[0019] In one embodiment of the invention, a diffraction lens (DOE) or light-scattering surface structure is formed in the optically effective surface of the lens element to be formed by means of a final contour mold. Suitable light-scattering surface structures include, for example, an amplitude modulation and / or (surface) roughness of at least 0.05 μm, particularly at least 0.08 μm, or are designed to have an amplitude modulation with a (surface) roughness of at least 0.05 μm, particularly at least 0.08 μm, depending on the circumstances. In this disclosure, particularly according to ISO 4287, roughness is specifically defined as Ra. In another embodiment of the invention, the light-scattering surface structure may include a structure mimicking the surface of a golf ball, or may be designed to mimic the surface of a golf ball.

[0020] Suitable light-scattering surface structures have been disclosed, for example, in German patent specifications 10 2005 009 556, DE 102 26 471 B4, and DE299 14 114 U1. Other suitable technical solutions for light-scattering surface structures have been disclosed in German patent specifications 1 099 964, DE36 02 262 C2, DE 40 31 352 A1, US 6 130 777, US 2001 / 0033726 A1, JP 2010-123307A, JP 2009-159810 A, WO 2018 / 177757 A1, and JP 2001-147403 A.

[0021] The present invention also relates to a method for manufacturing a vehicle headlight, wherein an optical lens element manufactured according to the above method is mounted in a headlight housing.

[0022] The present invention also relates to a method for manufacturing a vehicle headlight, wherein an optical lens element made according to the above method is placed in a headlight housing and mounted together with at least one light source to form a vehicle headlight.

[0023] The present invention also relates to a method for manufacturing a vehicle headlight, wherein an optical lens element manufactured according to the above method is mounted in a headlight housing together with at least one light source and a light shield to form a vehicle headlight, such that the edge of the light shield can be mapped as a cutoff line of light and dark by means of light emitted by the light source by the lens element.

[0024] The present invention also relates to a method of manufacturing a vehicle headlight for implementing matrix lights and / or adaptive high beams (e.g., HD-SSL), wherein an optical lens element manufactured according to the above method is mounted in the headlight housing, together with at least one light source and an additional lens, and the additional lens is used to generate a light distribution on the output surface of the light generated by the light source, such that the light distribution can be mapped by means of a lens element acting as a secondary lens. Particularly suitable additional lenses are disclosed, for example, in US 9,689,545 B2 (entirely incorporated by reference), US 9,851,065 B2 (entirely incorporated by reference), and DE 11 2017 000 180 A5 (entirely incorporated by reference).

[0025] The present invention also relates to a method for manufacturing a vehicle headlight for implementing matrix lights and / or adaptive high beams, wherein an optical lens element manufactured according to the above method is mounted together with at least one other lens element to form a lens, wherein, particularly in the headlight housing, at least one light source and an additional lens are mounted as a vehicle headlight and the additional lens is used to generate a light distribution on the output surface of the additional lens from the light source, such that the light distribution can be mapped by means of the lens.

[0026] The present invention also relates to a method of manufacturing an automobile, wherein headlights manufactured according to the above method are mounted on the front of the automobile.

[0027] The present invention also relates to a method of manufacturing an automobile, wherein headlights manufactured according to the above method are mounted on the front of the automobile, such that the light distribution can be mapped onto the environment in front of the automobile.

[0028] In the manufacture of optical lens elements, transparent plastics are processed, such as PC, PMMA, COC, COP, and amorphous PA. Elastic materials, such as thermoplastic elastomers, can also be processed.

[0029] In this disclosure, the (optical) lens element specifically refers to a headlight lens. In this disclosure, the (optical) lens element specifically refers to a condenser lens. In this disclosure, the pressed lens (or lens element) specifically refers to a lens with a volume of at least 50 cm². 3And / or a gateless lens (or lens element) with a thickness of at least 25 mm. Specifically, the following terms are used: a pre-molded part includes a gate and at least one pre-molded body. A pre-molded part may also include a gate having two or more pre-molded bodies. An injection molded part includes at least one gate and at least one lens element, or at least one gate and at least one lens. A lens element or lens includes a lens body and, where applicable, a lens edge or rim.

[0030] In the above context, the term "injection mold" should be specifically synonymous with injection cavity and / or tool. Advantageously, the first injection mold is part of the first injection molding machine (of the first injection tool), and the second injection mold is part of the second injection tool of the second injection molding machine, particularly. However, the first and second injection molds can also be implemented in a single injection tool, and particularly in a single injection molding machine. For this, see, exemplarily, the... Figure 14 Explanation.

[0031] In this disclosure, a gate specifically refers to a portion of a pre-molded injection part or injection part that is not part of the subsequent lens element. In this disclosure, it is specifically generated from plastic (melt) that solidifies into a mold in a delivery channel. In this disclosure, a gate specifically refers to a portion whose volume does not increase the volume of the "useful part," that is, the portion that increases the volume of the lens element. In this disclosure, a gate specifically includes objects referred to in English as "sprue," "runner," and "gate," or the material solidified therein. In this disclosure or in terminology, a gate is not specifically limited to the English term "sprue."

[0032] The disclosed method is particularly applicable to lenses with curved surfaces on both sides, that is, lenses where both the incident and exit surfaces are curved. The method is particularly applicable to lenses where both the incident and exit sides are convexly curved. The described method is particularly applicable to lenses disclosed in US 9,506,614 B2 (the entire contents of which are incorporated herein by reference).

[0033] In this disclosure, the term "cooling section" is synonymous with the term "cooling track." In this disclosure, the cooling section or cooling track is capable of slowly cooling portions that experience increased heat as they pass through it. The temperature experienced by the component decreases with increasing dwell time and further movement along the cooling section. Specifically, the portion to be cooled is placed on a conveying element similar to that in WO 2019 / 072325 A1.

[0034] In this disclosure, the edge or lens edge is particularly three-dimensional. In this disclosure, the edge or lens edge particularly has a certain volume. In this disclosure, the edge or lens edge particularly includes a supporting shoulder in the direction of the curved surface. When grinding a flat surface, the supporting shoulder can be used as a reference or reference surface. The supporting shoulder is particularly in a fixed relationship with the surface of the blank.

[0035] In this disclosure, the auxiliary lens is particularly arranged between the lens and the light source configuration. In this disclosure, the auxiliary lens is particularly arranged in the optical path between the lens and the light source configuration. In this disclosure, the auxiliary lens specifically refers to an optical device for forming a light distribution based on light, which is generated by the light source configuration and enters the auxiliary lens from this light source configuration. The light distribution is generated or formed, particularly by TIR, that is, by total internal reflection. However, the light distribution can also be generated or formed by light refraction or light diffraction. This method is also advantageously applicable, particularly to lenses having at least one flat surface or at least one concave surface. It is also particularly applicable to meniscus lenses and biconcave lenses.

[0036] In this disclosure, vehicle headlights specifically refer to adaptive high beams or matrix lights or SSL or HD-SSL.

[0037] The automobiles described in this invention specifically refer to land vehicles that can be used independently in road traffic. The automobiles described in this invention are not limited to land vehicles with internal combustion engines. Attached Figure Description

[0038] For further advantages and details, please refer to the following description of the embodiments. Wherein:

[0039] Figure 1 An example of a car equipped with vehicle headlights.

[0040] Figure 2 for Figure 1 The schematic diagram shows an embodiment of the vehicle headlights.

[0041] Figure 3 This is an embodiment of a matrix light or adaptive high beam.

[0042] Figure 4 This is another embodiment of a matrix light or adaptive high beam.

[0043] Figure 5 for Figure 2 An embodiment of the lighting device for the vehicle headlights shown is presented.

[0044] Figure 6 Another embodiment of the vehicle headlights as an alternative solution,

[0045] Figure 7 An embodiment of a method for manufacturing automotive lens elements,

[0046] Figure 8A An example of a pre-molded part,

[0047] Figure 8B An example of an injection-molded part,

[0048] Figure 8C After connecting the injection molding materials (injection molding materials) from the two pressing steps, Figure 8B The injection molded part shown is

[0049] Figure 8D As a modular automotive lens element,

[0050] Figure 9 A perspective view of a cut-off portion of an embodiment of the injection-molded part;

[0051] Figure 10 This diagram illustrates a cascade of two injection molding machines used to manufacture pre-formed lens elements, and a subsequent thermal surface treatment associated with the pressing step. This thermal surface treatment is used to achieve the contour of the optically effective surface (of the lens element) within predetermined tolerances.

[0052] Figure 11 This is a basic cross-sectional view of an embodiment of an injection molding machine.

[0053] Figure 12 This is an example of a basic arrangement scheme for pre-molded parts in the mold of an injection molding machine.

[0054] Figure 13 This is another embodiment of the basic arrangement scheme of pre-molded parts in the mold of an injection molding machine.

[0055] Figure 14 This is a basic cross-sectional view of another embodiment of the injection molding machine.

[0056] Figure 15 An embodiment of a pressing station for pressing the contour of the optically effective surface (of a lens element) within a preset tolerance, and

[0057] Figure 16 This is an example of integrating a heating device with a final contour mold. Detailed Implementation

[0058] Figure 1 A car 1 is shown with adaptive headlights or vehicle headlights 10, said headlights or vehicle headlights being used to adapt to the needs of the car 1. Figure 2 The environmental sensor 2 shown implements terrain-related or traffic-related lighting for the environment or road surface in front of the vehicle 1. Therefore, Figure 2The schematically shown vehicle headlight 10 has an illumination device 4, which is controlled by a controller 3 of the vehicle headlight 1. The light L4 generated by the illumination device 4 is emitted from the vehicle headlight 10 as an illumination pattern L5 by means of a lens 5, which may include one or more optical lens elements or headlight lenses. Figure 3 and Figure 4 Examples of corresponding lighting graphics are shown, where Figure 3 See web.archive.org / web / 20150109234745 / and http: / / www.audi.de / content / de / brand / de / vorsprung_durch_technik / content / 2013 / 08 / Audi-A8-erstrahlt-in-neuem-Licht.html (accessed September 5, 2019). Figure 4 See the webpage www.all-electronics.de / matrix-led-und-laserlicht-bietet-viele-vorteile / (accessed September 2, 2019). Figure 4 In the illustrated technical solution, the lighting pattern L5 includes an illuminated area L51, a dark area L52, and a turning light L53. Another headlight system can be found at www.next-mobility.news / led-im-fahrzeug-die-rolle-der-matrixscheinwerfer-und-was-sie-leisten-a-756004 / (accessed September 2, 2019).

[0059] Figure 5 An embodiment of the lighting device 4 is shown, wherein the lighting device includes a light source configuration 410 having a large number of individually adjustable areas or pixels. For example, it can be set to a maximum of 100 pixels, a maximum of 1000 pixels, or not less than 1000 pixels, which can be individually adjusted by means of a controller 3, i.e., can be individually turned on or off. The lighting device 4 may also include an additional lens 411 for producing an illumination pattern (such as L4) on the light-emitting surface 412 according to the corresponding controlled area or pixel of the light source configuration 410 or the light L41 incident on the additional lens 411 accordingly.

[0060] DE 10 2017 105 888 A1 or refer to Figure 6 The described headlights, for example, reveal another applicable field of lenses made according to the present invention. Among them, Figure 6An exemplary light module (headlight) M20 is shown, which includes light-emitting units M4 having multiple matrix-arranged (point-like) light sources, each emitting light ML4 (with Lambertian radiation characteristics). The light module also includes a concave lens M5 and a projection lens M6. Figure 6 As shown in the example illustrated in DE 10 2017 105 888 A1, the projection lens M6 comprises two lenses arranged sequentially in the optical path, which are manufactured according to a method equivalent to the disclosed method. The projection lens M6 maps the light ML4 emitted by the light-emitting unit M4 and the light ML5 further formed after passing through the concave lens M5 as the total light distribution ML6 of the optical module M20 onto the road surface in front of the vehicle equipped with (or fitted with) the optical module or headlight.

[0061] The optical module M20 has a controller, indicated by reference numeral M3, which controls the light-emitting unit M4 based on parameters from the sensing mechanism or the environmental sensing mechanism M2. The concave lens M5 has a concave, curved exit surface on the side opposite to the light-emitting unit M4. The exit surface of the concave lens M5 redirects light ML4, which enters the concave lens M5 from the light-emitting unit M4 at a large beam angle, towards the edge of the concave lens by means of total internal reflection, preventing the light from passing through the projection lens M6. DE 10 2017 105 888 A1 refers to the following beams as beams emitted from the light-emitting unit M4 at a “large beam angle”: (in the absence of the concave lens M5 in the optical path) beams that, based on optical aberrations, are poorly, particularly unclearly, mapped onto the road surface by means of the projection lens M6, and / or beams that may form scattered light, which reduces the contrast of the mapping on the road surface (see DE 10 2017 105888 A1 for this point). The projection lens M6 can only clearly map light with an angle limited to approximately + / -20°. Therefore, by arranging a concave lens M5 in the optical path, beams with angles greater than + / -20°, especially greater than + / -30°, are prevented from hitting the projection lens M6.

[0062] The light-emitting unit M4 can be constructed in different ways. According to one technical solution, each point light source in the light-emitting unit M4 includes a semiconductor light source, particularly a light-emitting diode (LED). The LEDs can be controlled individually or in groups to turn them on or off, or dim them. The light module M20 has, for example, more than 1000 individually controllable LEDs. The light module M20 can particularly be constructed as a so-called pAFS (micro-structured adaptive front-lighting system) light module.

[0063] According to one alternative, the light-emitting unit M4 has a semiconductor light source and a DLP or a micromirror array comprising a large number of micromirrors, which can be individually controlled or flipped, wherein each of the micromirrors forms one of the point light sources of the light-emitting unit M4. The micromirror array, for example, comprises at least one million micromirrors, which can be flipped at a frequency of up to 5000 Hz.

[0064] Figure 7 For example use Figure 10 An embodiment of a method for manufacturing (optical) lens elements or (optical) automotive lens elements using the illustrated apparatus is described. In step 111, injection pressing (injection) is performed. Figure 8A The pre-molded part 20 is shown. Among them, Figure 8A In the attached figure, reference numeral 21 indicates the gate, and reference numerals 22 and 23 each indicate a pre-molded part.

[0065] In step 112, the pre-molded part 20 is cooled in the injection mold, and then in step 113 it is removed and transported to a cooling station or a storage device (also a cooling station) outside the injection mold.

[0066] The next step is step 114, in which the pre-molded part 20 is arranged in the second injection mold. This is followed by an injection molding step similar to injection step 111 or injection molding step 115, wherein... Figure 8B The pre-molded part 20 is shown to be injection molded into part 30. Wherein, Figure 8A and Figure 8B In the attached figure, reference numeral 21 indicates the gate of the pre-molded injection part 20 (see above). Figure 8B Reference numeral 31 in the figure indicates another gate, wherein the two gates 21 and 31 form Figure 8B The integral gate is indicated by reference numeral 41 in the attached drawing. Figure 8B Reference numeral 32 in the figure indicates injection molding material used for injection molding to encapsulate pre-molded body 22 to form pre-lens element 42, and reference numeral 33 indicates injection molding material used for injection molding to encapsulate pre-molded body 23 to form pre-lens element 43. Figure 8C The diagram shows a schematic or schematic sketch of an injection-molded part, which includes preformed lens elements 42 and 43 and an integral gate 41 at which the injection molding materials from the two injection compression steps are joined together. Preformed lens element 42 includes a lens body 420 and an edge 421. Preformed lens element 43 includes a lens body 430 and an edge 431. Figure 9 A specific embodiment of the injection-molded part is shown. The blind protrusions (represented by reference numerals 441, 442, 443, and 444) may be omitted.

[0067] Step 115 is followed by step 116, in which the injection molded part is cooled. This is followed by step 117, in which the injection molded part is removed from the injection mold and further cooled. Then, step 118, in which the integral gate 41 is separated from the preformed lens elements 42 and 43, thereby isolating the preformed lens elements 42 and 43. In step 119, a (optical) lens element is manufactured from the preformed lens element 42 or 43. Step 119 may also be performed before step 118.

[0068] Figure 10 Showing the reference for implementation Figure 7 This is a schematic diagram of an apparatus for the described method of manufacturing an optical lens element. P1 represents an injection press (injection molding machine) or injection mold for manufacturing pre-molded parts 20. S1 represents a storage device, and K1 represents a cooling device. The cooling device K1 is used to transfer the pre-molded parts 20 at a suitable temperature to the injection press (injection molding machine) or injection mold P2 to manufacture injection molded parts 30. Furthermore, each pre-molded part is fed into the storage device S1 in stages, thereby maintaining, for example, the daily production of pre-molded parts. This allows for compensation for mold changes and malfunctions by separating the processes performed on the injection press (injection molding machine) or injection molds P1 and P2, while simultaneously combining them. Therefore, mold changes and maintenance involving the injection press or injection molds P1 and P2 do not need to be synchronized. For example, if the injection press P2 does not receive any pre-molded parts 20, these pre-molded parts are placed in the storage device S1. If the cooling section K1 is empty, the handling robot will take the pre-molded part out of the memory S1 and transport it to the injection press (injection molding machine) P2.

[0069] In another technical solution, pre-formed lens elements are manufactured in three injection molding steps. The first injection molding step is performed on an injection press (injection molding machine) of injection mold P1, and the second and third injection molding steps are performed on an injection press (injection molding machine) of injection mold P2. Specifically, sixteen pre-formed injection bodies are injected in one injection molding step, eight pre-formed injection bodies are injected on the injection press (injection molding machine) of injection mold P2 in the second molding step, and eight pre-formed lens elements are injected in the third injection molding step.

[0070] Figure 11 An exemplary embodiment of an injection molding machine 500 is shown, which is used as an injection molding machine having an injection mold P1 or P2. The injection molding machine 500 includes an injection unit 50 having a worm gear 52 and a heating system 51 for liquefying plastic, feeding the plastic in granular form into a feeding device 53. The plastic liquefied by means of the heating system 51 is indicated by reference numeral 54.

[0071] Subsequently, liquefied plastic 54 is pressed into the hot channel system 80 and injected from there into the injection molding tool 60 via the hot channel nozzle 81. The injection molding tool 60 includes two sub-molds 61 and 62, which can be separated, depending on the object being manufactured, to remove the pre-molded part or injection molded part. Reference numeral 72 indicates a cooling channel in the injection molding tool 60.

[0072] In this embodiment, the pre-molded part is pressed, specifically, as... Figure 12 As illustrated, eight pre-molded parts are pressed in one pressing step. Reference numeral 200 indicates a pre-molded part having two pre-molded bodies 202 and 203 connected by a gate 201, and 204 indicates the injection point of the pre-molded part 200. Figure 11 Reference numeral 71 in the figure indicates an ejector adapted to press against the pre-molded bodies 202 and 203 to eject them from the sub-mold 61. Figure 12 The schematic diagram shows the pre-molded injection part 200 as viewed from sub-mold 62 toward sub-mold 61. Ejector 71 and the other ejectors shown in the diagram are from... Figure 11 The cross-section protrudes, thus it can be seen from the diagram alone that the ejector does not act on gate 201, but rather on preforms 202 and 203. Injection molded parts are manufactured in a similar manner. Particularly advantageously, when changing the injection molded part or the preform to be injected, a new mold is set up to injection mold another preform using the same hot runner system. That is, the injection point 204 of the preform 200 is... Figure 13 The injection points 204' of the pre-molded injection part 200' shown are at the same position. The pre-molded injection part 200' includes two pre-molded bodies 202' and 203' connected by a gate 201'.

[0073] For example, it can be used Figure 14 The injection molding machine 500' shown is used to manufacture injection molded parts. This injection molding machine is an improvement upon the injection molding machine 500. Figure 11Like reference numerals denote similar or identical elements. The injection molding tool of injection molding machine 500', indicated by reference numeral 60', includes two sub-molds 61' and 62'. Unlike injection molding machine 500, injection molding machine 500' has two hot runner systems 80' and 80" respectively. Liquid plastic is supplied to hot runner system 80" via injection unit 50, and liquid plastic is supplied to hot runner system 80' via injection unit 50'. Pre-molded parts and injection molded parts can be injected in injection molding machines like injection molding machine 500'. The hot channel system 80" supplies or fills the injection mold of the injection tool 60' with liquid plastic for injecting the preformed injection body. After injection, the preformed injection body is removed and cooled in the cooling device K1 or / and a certain storage device S1. After sufficient cooling, the preformed injection body is inserted into the injection mold of the injection tool 60' of the injection molding machine 500' corresponding to the hot channel system 80'. In these injection molds corresponding to the hot channel system 80', the preformed injection body is injection molded and encapsulated into a preformed injection part or a preformed lens element.

[0074] In one exemplary embodiment of step 119, the preformed lens element is cooled in and / or removed from the injection press or injection mold P2 such that the plastic solidifies, wherein subsequently... Figure 10 As shown, by means of Figure 10 The heating device HZV shown heats at least one surface of the pre-formed lens element that serves as an optically effective surface, such that the plastic is malleable on the optically effective surface, with a malleable depth, particularly not exceeding 1000 micrometers, particularly not exceeding 500 micrometers, particularly not exceeding 100 micrometers, wherein, as... Figure 10 As shown, the pre-fabricated lens element is pressed into a lens element with an optically effective surface in the final contour mold EKF.

[0075] Figure 15 This diagram shows the PS (Pressure Processing) principle for a pressing station used to press lens elements from pre-formed lens elements. The PS of the pressing station has an upper pressing assembly PO and a lower pressing assembly PU. The mold OF (upper mold), which moves by means of a pressing driver or by means of an actuator O10, is brought close to the mold UF (lower mold), which moves by means of a pressing driver or by means of an actuator U10, to perform pressing.

[0076] The mold OF and / or mold UF is one embodiment of the final contour mold EKF. Therefore, for example, the upper side of the preformed lens element can be heated, and then pressed using the mold OF. Alternatively or supplementarily, for example, the lower side of the preformed lens element can be heated, and then pressed using the mold UF. The mold OF and / or mold UF can also be an embodiment of the heating device HZE. Therefore, for example, the preformed lens element can be placed in the mold UF, heated in the mold UF, and then pressed by bringing the mold OF and mold UF close together, so that the mold UF presses the desired optically effective surface into the preformed lens element to manufacture an optical lens element.

[0077] The mold UF is connected to a movable mold-side connector U12, which in turn is connected to a movable actuator-side connector U11 via movable guide rods U51 and U52. The actuator U10 is also connected to the movable actuator-side connector U11, allowing the mold UF to move via the actuator U10. The movable guide rods U51 and U52 extend through grooves in the fixed guide element UO, thereby preventing, reducing, or limiting the deflection or movement of the movable guide rods U51 and U52 and the mold UF perpendicular to the direction of movement.

[0078] The pressing assembly PO includes an actuator O10 that moves the mold OF and is connected to a movable guide element O12. The pressing assembly PO also includes a frame formed by a fixed actuator-side connector O11, a fixed mold-side connector O14, and fixed guide rods O51 and O52 that connect the fixed actuator-side connector O11 to the fixed mold-side connector O14. The fixed guide rods O51 and O52 are guided through grooves in the movable guide element O12, thereby impeding, reducing, or preventing movement or deflection of the mold OF orthogonal to the direction of movement of the actuator O10 or the mold OF.

[0079] In the illustrated embodiment, the pressing assembly PO is combined in such a way that the fixed guide element UO is equivalent to the fixed mold side connector O14. Through the combination or interlocking of these two pressing assemblies PO and PU at the pressing station PS, extremely high quality (especially in the form of contour precision) is achieved for the lens element or headlight lens to be pressed.

[0080] Different force-displacement curves and displacement-time curves can be achieved for the pressing motion system:

[0081] (i) Turning the press on and off

[0082] (ii) Close the press, hold for a time (for relaxation and retardation of the edge layer (within the optically effective surface area)), then open.

[0083] (iii) Combining curves (i) and (ii), for example, multiple pressing for calibrating / improving surface quality.

[0084] (iv) Combining curves (i) to (iii) with the vibration superposition of the tool system

[0085] In the described method, the heating device HZV and the final contour mold EKF are implemented as separate units or as units arranged sequentially. However, as... Figure 15 As shown in the options, the heating device HZV and the final contour mold EKF can also be integrated together, for example, via a deflectable radiant heater HST. The mold UF and / or mold OF can be heated by means of the radiant heater. After heating, the preformed lens element can be placed into the heated mold UF, as appropriate. Subsequently, the upper side of the preformed lens element can be heated by means of the radiant heater HST, such that the temperature near the surface of the preformed lens element is higher than TG. The mold OF can be heated simultaneously by means of the heat output of the radiant heater HST. Then, the mold UF and mold OF are brought close together so that the desired lens element is pressed or imprinted by the preformed lens element through the closed mold formed by the mold UF and mold OF.

[0086] It can also be used with the help of Figure 16 The diagram illustrates a scheme for heating a mold. Here, OF' represents the mold corresponding to mold OF, and mold UF' represents the mold corresponding to mold UF. In a variant of mold OF, mold OF' has a heating channel HZK for heating mold OF'. A corresponding heating channel HZK may also be provided in mold UF'. Alternatively, as shown, a heating device HZO is provided, which forms a contour-matched resistance heating element, such as a milled copper insert, which is electrically and thermally insulated from the rest of mold UF.

[0087] Appendix Label Table

[0088] 1. Car

[0089] 2. Environmental sensing mechanism

[0090] 3 Controllers

[0091] 4 lighting fixtures

[0092] 5 lenses, including headlight lenses / lens elements

[0093] 10 Vehicle headlights

[0094] 20 Precast Injection Molded Parts

[0095] 21 (First) Gate

[0096] 22, 23 Precast injection molded parts

[0097] 30 Injection Molded Parts

[0098] 31 (Second or additional) gate

[0099] 32, 33 Injection molding materials / injection compression materials used for encapsulating pre-molded bodies

[0100] 41. Gate or integral gate

[0101] 42, 43 Injection molded components or pre-fabricated lens components

[0102] 50, 50' injection molding unit

[0103] 51 Heating System

[0104] 52 worm gear

[0105] 53 Feeding device

[0106] 54. Liquefied plastics

[0107] 60, 60' injection molding tool

[0108] Sub-molds 61, 62, 61', 62'

[0109] 71 Ejector

[0110] 72 Cooling Channels

[0111] 80, 80', 80" Hot aisle system

[0112] 81 Hot Channel Nozzle

[0113] 111, 112, 113, 114,

[0114] 115, 116, 117, 118,

[0115] Step 119

[0116] 200, 200' Precast Injection Molded Parts

[0117] 201, 201' gate

[0118] 202, 202', 203, 203' Precast injection molded parts

[0119] Injection points 204, 204'

[0120] 410 Light Source Configuration

[0121] 411 Additional Lens

[0122] 412 Light-emitting surface

[0123] 420, 430 lens body

[0124] 421, 431 Lens element edges

[0125] 441, 442, 443, 444 Blind protrusions

[0126] 500, 500' injection molding machine

[0127] P1, P2: Injection press (injection molding machine) or injection mold of injection molding machine.

[0128] K1 Cooling Equipment

[0129] S1 memory

[0130] HZV, HZO heating devices

[0131] EKF Final Contour Mold

[0132] HZK heating channel

[0133] HAST Radiant Heater

[0134] L4 light

[0135] L5 Lighting Graphics

[0136] L41 Incident light

[0137] L51 Illuminated Area

[0138] L52 Dark Zone

[0139] L53 Turning Light

[0140] M2 Environmental Sensing Mechanism

[0141] M3 controller

[0142] M4 LED unit

[0143] M5 concave lens

[0144] M6 projection lens

[0145] M20 headlights

[0146] ML4 light

[0147] ML5 light

[0148] ML6 light distribution

[0149] PS compression station

[0150] PO compression component

[0151] PU pressing component

[0152] OF, OF' upper mold

[0153] UF, UF' lower mold

[0154] U10, O10 actuators

[0155] U11, U12 movable connectors

[0156] U51, U52 movable guide rods

[0157] UO fixed guide element

[0158] O11 Actuator Side Connector

[0159] O12 movable guiding element

[0160] O14 Mold Side Connector

[0161] O51 and O52 are fixed guide rods.

Claims

1. A method of manufacturing an optical lens element for illumination purposes, wherein injection molding plastic is used to form a pre-molded body (22) and / or a pre-molded part (20) by means of a first injection mold, the injection plastic being a transparent plastic liquefied by heating, the pre-molded part comprising at least one pre-molded body (22) and at least one first gate (21) connected to the pre-molded body (22), wherein the pre-molded body (22) and / or the pre-molded part (20) is subsequently cooled outside the first injection mold, and wherein the pre-molded part is subsequently at least partially formed in a second injection mold by means of other injection plastic. The injection body (22) is injection molded and / or injection molded into a preformed lens element (42, 43), the other injection plastic being a transparent plastic liquefied by heating, wherein the preformed lens element (42, 43) is cooled such that the plastic solidifies, and wherein at least one surface of the preformed lens element (42, 43) configured as an optically effective surface is subsequently heated such that the plastic is malleable on the optically effective surface to a depth not exceeding 1000 micrometers, wherein the preformed lens element (42, 43) is pressed into a lens element having the optically effective surface in a final contour mold.

2. The method according to claim 1, characterized in that, When the preformed lens elements (42, 43) are pressed into lens elements having the optically effective surfaces in a final contour mold, at least 90% of the temperature of the preformed lens elements (42, 43) is below the TG of the plastic.

3. A method for manufacturing a vehicle headlight (10), characterized in that, An optical lens element made according to the method of claim 1 or 2 is installed in a headlight housing.

4. A method for manufacturing a vehicle headlight (10), characterized in that, An optical lens element made according to the method of claim 1 or 2 is placed in a headlight housing and mounted together with at least one light source to form a vehicle headlight (10).

5. A method for manufacturing a vehicle headlight (10), characterized in that, An optical lens element made according to the method of claim 1 or 2 is mounted together with at least one light source and a light shield in a vehicle headlight, such that the edge of the light shield can be mapped as a cutoff line of light and dark by means of the light emitted by the light source by the lens element.

6. A method for manufacturing a vehicle headlight (10) for implementing matrix lights and / or adaptive high beams, characterized in that, An optical lens element made according to the method of claim 1 or 2 is mounted together with at least one light source and an additional lens into a vehicle headlight (10), wherein the additional lens is used to generate a light distribution on the output surface of the additional lens from the light generated by the light source, such that the light distribution can be mapped by means of the lens element acting as a secondary lens.

7. A method for manufacturing a vehicle headlight (10) for implementing matrix lights and / or adaptive high beams, characterized in that, An optical lens element made according to the method of claim 1 or 2 is mounted together with at least another lens element to form a lens, wherein at least one light source and an additional lens are mounted as a vehicle headlight (10) and the additional lens is used to generate a light distribution on the output surface of the additional lens from the light generated by the light source, such that the light distribution can be mapped by means of the lens.

8. A method for manufacturing an automobile, characterized in that, The vehicle headlight (10) made according to any one of claims 3 to 7 is mounted on the front of the vehicle (1).

9. A method for manufacturing an automobile, characterized in that, The vehicle headlight (10) made according to claim 6 or 7 is mounted on the front of the vehicle (1) such that the light distribution can be mapped onto the environment in front of the vehicle (1).

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