Method for manufacturing a lens system
By using injection molding and UV curing technology to manufacture lens systems, the problems of high cost and low efficiency in lens alignment have been solved, achieving precise alignment and cost reduction.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- ZKW GRP GMBH
- Filing Date
- 2022-06-07
- Publication Date
- 2026-06-30
AI Technical Summary
In the existing lens system manufacturing process, the manufacturing tolerance of the lens is difficult to control, resulting in high alignment costs and increased expenses. At the same time, the existing methods are inefficient.
The lens system is manufactured using injection molding. A second lens is formed using a UV-curable material and cured by a UV light source to ensure that the first and second lenses are precisely coordinated in relative positions, thus forming an achromatic lens system.
This achieves precise alignment of the lens system, eliminating the need for subsequent calibration, shortening manufacturing time, reducing costs, and improving efficiency.
Smart Images
Figure CN115503184B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a method for manufacturing a lens system, wherein the method includes the following steps:
[0002] - An injection molding apparatus is provided, comprising a first half-mold and a second half-mold, wherein the injection molding apparatus is configured to manufacture an optical lens by means of an injection molding method, wherein the first half-mold has a holding section on its side facing the second half-mold, the holding section being configured to fix the lens in a predetermined position relative to the second half-mold.
[0003] - A first lens is provided, wherein the first lens is made of a first material having a first refractive index and has a first external shape.
[0004] - A first lens is introduced and fixed in the holding section, wherein the first lens is fixed in the holding section such that the first optically active surface of the first lens faces the second half-mode, and the second optically active surface of the first lens faces away from the second half-mode.
[0005] - The injection molding device is closed by joining the first half mold and the second half mold together, wherein the second half mold has a recessed mold on the side facing the first half mold, wherein, in the closed state of the injection molding device, a cavity capable of being filled with injection molding material is constructed between the first lens and the recessed mold, wherein the cavity is designed as a female mold of the second external shape of the second lens, wherein the first external shape of the first lens and the second external shape of the second lens are different.
[0006] The present invention also relates to a lens system comprising a first lens formed of a first material having a first refractive index and a second lens formed of a second material having a second refractive index, wherein the first material and the second material, as well as the first refractive index and the second refractive index, are different.
[0007] The present invention also relates to a motor vehicle headlight. Background Technology
[0008] This type of method for manufacturing lens systems is known from existing technologies. Because a lens system typically consists of multiple lenses that work together optically, the manufacturing tolerances of each lens must be minimized during the manufacturing process. Tolerance should be understood as the deviation of dimensions (e.g., the ideal shape of the lens) from a standard state, a deviation that does not negatively impact the function of the system. In a lens system, the alignment of the manufactured lenses relative to each other is adversely associated with higher costs and expenses. Furthermore, for cost reasons, it is important to design the manufacturing process not only as accurately (i.e., with minimal tolerances) but also quickly and efficiently. Summary of the Invention
[0009] The objective of this invention is to mitigate or eliminate the disadvantages of the prior art. Therefore, a particular object of this invention is to provide a method for manufacturing a lens system, thereby improving the manufacturing process of the lens system.
[0010] This task is accomplished by a method having the features of claim 1. Preferred embodiments are given in the dependent claims.
[0011] According to the present invention, the method comprises the following steps:
[0012] - Injection material is introduced into a recessed mold to form a second lens in a cavity, wherein the second lens has a first optically active surface and a second optically active surface, wherein the second lens is formed at the first lens such that the first optically active surface of the second lens contacts the first optically active surface of the first lens, wherein the injection material forming the second lens is a second material having a second refractive index, wherein the first material and the second material are different, wherein the first refractive index and the second refractive index are different such that the first lens and the second lens constitute an achromatic lens system, wherein the second material is a UV-curable material, wherein the second half-mold has a region that is translucent to UV light, and this region is designed and positioned such that UV light can radiate from outside the injection molding apparatus onto the second lens.
[0013] - Provides UV light source,
[0014] - The second lens is cured by UV light radiation from the UV light source, wherein the UV light radiates onto the second lens through the UV light-transmittable area of the second half-mode, so as to cure the second lens.
[0015] This provides the following advantages: the second lens is directly applied to the first optically active surface of the first lens, thereby precisely coordinating the first and second lenses in their relative positions. Advantageously, post-calibration of the two lenses relative to each other is unnecessary. Furthermore, the curing time and therefore the manufacturing process time are reduced by curing the second lens with the aid of UV light. The second material can be epoxy resin or acrylate. The first material can be glass or polymethyl methacrylate. In particular, the first and second lenses form an achromatic lens system, wherein the lens system may also have more than two lenses. Preferably, the first optically active surface of the first lens and the first optically active surface of the second lens are molded complementaryly to each other. In other words, the first optically active surface of the first lens is the negative of the first optically active surface of the second lens. In this regard, the optically active surfaces of a lens are the two surfaces on which light hits and escapes when the lens is illuminated. For example, in a biconvex lens, the two curved surfaces where light is refracted are the optically active surfaces.
[0016] The first lens can be configured to be a convex lens, preferably a biconvex lens.
[0017] The second lens can be configured to be a concave lens, preferably a biconcave lens.
[0018] The recessed mold can be configured such that it is formed of silicone, preferably polydimethylsiloxane. The second recessed mold is preferably formed of a UV-transparent material. Preferably, the entire second half of the injection molding device is formed of a UV-transparent material, such as silicone.
[0019] The recessed mold can be configured to have steps, such that the second lens formed from the injection-molded material has a reduced volume compared to a lens manufactured in a recessed mold without steps. Filling a recessed mold without steps with injection-molded material can, for example, construct a biconvex lens, wherein the recessed mold with steps has a reduced volume compared to a biconvex lens.
[0020] The second lens can be configured such that the section of the second lens facing away from the first lens has a reduced volume compared to a lens without a stepped structure due to the step structure. In particular, the stepped second lens can be an asymmetric lens, wherein the first and second optically active surfaces of the second lens can have different shapes.
[0021] The contact between the first optically active surface of the second lens and the first optically active surface of the first lens can be configured to be a single, seamless surface, particularly without gaps. Since there are no air gaps between the lenses, the following advantage is achieved: no undesirable light scattering occurs. A layer or film containing an adhesive (e.g., silicone oil) can be applied between the lenses to achieve better adhesion between the first and second lenses. Preferably, the adhesive layer or film is applied to the first optically active surface of the first lens before the injection molding device is closed. The adhesive is preferably configured to be transparent.
[0022] It can be configured such that, in the manufacturing state of the lens system, the first lens and the second lens are oriented coaxially with each other.
[0023] The concave mold can be designed such that the second optically active surface of the second lens has a Fresnel lens-like surface. This yields the following advantages: less material is required for the second lens, which reduces manufacturing costs.
[0024] According to the present invention, a lens system is provided, comprising a first lens formed of a first material having a first refractive index and a second lens formed of a second material having a second refractive index, wherein the first material and the second material, as well as the first refractive index and the second refractive index, are different, and wherein the lens system is an achromatic lens system manufactured by the method of the present invention.
[0025] The lens system can be configured to have multiple lenses, wherein at least two lenses are constructed as an achromatic lens system, which is manufactured by the method according to the invention.
[0026] According to the present invention, a motor vehicle headlight is provided, which includes an illumination device for generating and radiating light distribution, wherein the illumination device has a lens system manufactured by the method according to the present invention.
[0027] Within the scope of this specification, the terms “upper,” “lower,” “horizontal,” and “vertical” should be understood as an orientation description when the injection molding apparatus is arranged in its normal operating position during the manufacturing process. Attached Figure Description
[0028] The invention will now be explained in more detail with reference to preferred embodiments; however, the invention should not be limited to these embodiments. Wherein:
[0029] Figure 1 A schematic diagram of an injection molding apparatus is shown in the first method step according to the method of the present invention;
[0030] Figure 2 A schematic diagram of the injection molding apparatus in the second method step is shown;
[0031] Figure 3 A schematic diagram of the injection molding apparatus in the third method step is shown;
[0032] Figure 4 A schematic diagram of the injection molding apparatus in the fourth method step is shown;
[0033] Figure 5 A first embodiment of a lens system manufactured using the method according to the invention is shown; and
[0034] Figure 6 A second embodiment of a lens system manufactured using the method according to the present invention is shown. Detailed Implementation
[0035] The accompanying drawings are schematic and greatly simplified for clarity, in which non-essential components of the injection molding unit are not shown.
[0036] Figure 1 The first method steps for manufacturing a lens system are shown.
[0037] The first step includes providing an injection molding apparatus 1. The injection molding apparatus 1 includes a first half-mold 1a and a second half-mold 1b. The injection molding apparatus 1 is configured to manufacture an optical lens by means of an injection molding method.
[0038] The first half-mold 1a has a retaining section 2, which is arranged on the side of the first half-mold 1a facing the second half-mold 1b. The retaining section 2 is configured to fix the lens in a predetermined position relative to the second half-mold 1b. The positioning and fixing of the first lens are based on certain preset values preset by the lens system to be manufactured.
[0039] The method includes the further step of providing a first lens 3. The first lens 3 is made of a first material having a first refractive index and has a first external shape. For example, the first lens 3 may be made of glass. Preferably, the first lens is a convex lens, and more preferably a biconvex lens.
[0040] Figure 2 Further method steps are shown, including introducing and fixing a first lens 3 at a holding section 2. In this step, the first lens 3 is positioned and fixed at the holding section 2 of the first half-mode 1a. The first lens 3 is fixed at the holding section 2 such that the first optical active surface 3a of the first lens 3 faces the second half-mode 1b, and the second optical active surface 3b of the first lens 3 faces away from the second half-mode 1b (see [reference]). Figure 3 ).
[0041] Figure 3 Further method steps are shown, including closing the injection molding device. The injection molding device is closed by bringing together the first half-mold 1a and the second half-mold 1b.
[0042] The second half-mold 1b has a recessed mold 4 on its side facing the first half-mold 1a, wherein, in the closed state of the injection molding device 1, a cavity 5 capable of being filled with injection molding material is formed between the first lens 3 and the recessed mold 4. The recessed mold 4 may also be referred to as a filling mold or an injection mold. The recessed mold 4 is essentially a recess in the second half-mold 1b that can be filled with injection molding material. The recessed mold 4 and / or the second half-mold 1b are formed, for example, of silicone, preferably of polydimethylsiloxane.
[0043] Cavity 5 is designed as a female mold with a second external shape for the second lens 6, wherein the external shape of the first lens 3 and the external shape of the second lens 6 are different. Cavity 5 is essentially constructed between the recessed mold 4 of the second half mold 1b and the first optical active surface 3b of the first lens 3. The injection molding apparatus includes a supply device (not shown) for injection molding material, wherein the supply device is configured to deliver injection molding material into cavity 5.
[0044] Figure 4Further method steps are shown, including introducing injection molding material into a recessed mold 4. By introducing the injection molding material into the recessed mold 4 or cavity 5, a second lens 6 formed of the injection molding material is formed in the cavity 5. The second lens 6 has a first optically active surface 6a and a second optically active surface 6b. The second lens 6 is formed at the first lens 3 such that the first optically active surface 6a of the second lens 6 contacts the first optically active surface 3a of the first lens 3. The second lens 6 is preferably a concave lens, especially a biconcave lens. In the manufacturing state of the lens system, the first lens 3 and the second lens 6 are particularly coaxially oriented with each other.
[0045] The contact between the first optical active surface 6a of the second lens 6 and the first optical active surface 3a of the first lens 3 is particularly seamless and preferably without gaps. The first optical active surface 3a of the first lens 3 and the first optical active surface 6a of the second lens 6 are constructed to complement each other.
[0046] The injection molding material forming the second lens 6 includes a second material having a second refractive index. The first material of the first lens is different from the second material of the second lens, wherein the first and second refractive indices are so different that the first lens 3 and the second lens 6 constitute an achromatic lens system. The second material is a material that can be cured using UV light.
[0047] The second half-mold 1b has a region that is transparent to UV light, and this region is designed and positioned such that UV light can radiate from outside the injection molding device onto the second lens 6. For example, the second half-mold can be made entirely of a UV-transparent material.
[0048] In a further method step, a UV light source (not shown) is provided.
[0049] Further method steps include curing the second lens 6 by UV light radiation from a UV light source, wherein the UV light radiates onto the second lens 6 through a UV light-transmittable region of the second half-mode 1b, so as to cure the second lens.
[0050] Figure 5 A lens system manufactured using the method according to the invention is shown, comprising a first lens 3 formed of a first material and having a first refractive index. The lens system also includes a second lens 6 formed of a second material and having a second refractive index. The first and second materials, as well as the first and second refractive indices, are different and chosen such that the lens system is an achromatic lens system. In other words, the first lens 3 and the second lens 6 form an achromatic system.
[0051] Figure 6A second embodiment of a lens system manufactured using the method according to the invention is shown. The recessed mold 4 has steps, which are such that the second lens 6, formed from injection molding material, interacts with the recessed mold without steps (see [reference]). Figure 3 and Figure 4 Lenses manufactured in this way have a smaller volume compared to those manufactured in other ways.
[0052] The steps of the second lens 6 are located in the section of the second lens 6 that is away from the first lens 3. The step-like section has a reduced volume compared to a lens without steps.
[0053] In order to form a basis Figure 6 In the second embodiment, the concave mold 4 is designed such that the second optical active surface 6b of the second lens 6 has a Fresnel lens-like surface. The first optical active surface 6a is constructed to be concave and is defined by the convex shape of the first lens 3.
Claims
1. A method for manufacturing a lens system, wherein, The method includes the following steps: - An injection molding apparatus (1) is provided, the injection molding apparatus comprising a first half-mold (1a) and a second half-mold (1b), wherein the injection molding apparatus (1) is configured to manufacture an optical lens by means of an injection molding method, wherein the first half-mold (1a) has a holding section (2) on its side facing the second half-mold (1b), the holding section being configured to fix the lens in a predetermined position relative to the second half-mold (1b). - A first lens (3) is provided, wherein the first lens (3) is made of a first material having a first refractive index and has a first external shape. - The first lens (3) is introduced and fixed in the holding section (2), wherein the first lens (3) is fixed in the holding section (2) such that the first optical active surface (3a) of the first lens (3) faces the second half-mode (1b), and the second optical active surface (3b) of the first lens (3) faces away from the second half-mode (1b). - Before closing the injection molding device, an adhesive layer or adhesive film is applied to the first optically active surface (3a) of the first lens (3). - The injection molding device is closed by joining the first half-mold (1a) and the second half-mold (1b) together, wherein the second half-mold (1b) has a recessed mold (4) on the side facing the first half-mold (1a), wherein, in the closed state of the injection molding device (1), a cavity (5) capable of being filled with injection molding material is constructed between the first lens (3) and the recessed mold (4), wherein the cavity (5) is designed as a female mold of the second external shape of the second lens (6), wherein the first external shape of the first lens (3) and the second external shape of the second lens (6) are different. Its features are, - After closing the injection molding device, injection material is introduced into the recessed mold (4) to form a second lens (6) in the cavity (5), wherein the second lens (6) has a first optically active surface (6a) and a second optically active surface (6b), wherein the second lens (6) is formed at the first lens (3) such that the first optically active surface (6a) of the second lens (6) contacts the first optically active surface (3a) of the first lens (3), wherein the injection material forming the second lens (6) is a second material having a second refractive index, wherein the first material is different from the second material, wherein the first refractive index and the second refractive index are so different that the first lens (3) and the second lens (6) constitute an achromatic lens system, wherein the second material is a material that can be cured by UV light, wherein the second half mold (1b) has a region that is transparent to UV light, which is designed and provided such that UV light can radiate from outside the injection molding device onto the second lens (6). - Provides UV light source, - The second lens (6) is cured by UV light radiation from the UV light source, wherein the UV light radiates onto the second lens (6) through the UV light-transmittible area of the second half-mode (1b) to cure the second lens. The recessed mold (4) has steps such that the second lens (6) formed from the injection molding material has a reduced volume compared to a lens manufactured in a recessed mold without steps, and the recessed mold (4) is designed such that the second optically active surface (6b) of the second lens (6) has a Fresnel lens-like surface.
2. The method according to claim 1, wherein, The first lens (3) is a convex lens.
3. The method according to any one of the preceding claims, wherein, The second lens (6) is a concave lens.
4. The method according to claim 1 or 2, wherein, The recessed mold (4) is formed of silicone.
5. The method according to claim 1, wherein, The section of the second lens (6) that is away from the first lens (3) has a reduced volume compared to a lens without a ladder, due to the ladder structure.
6. The method according to claim 1 or 2, wherein, The contact between the first optical active surface (6a) of the second lens (6) and the first optical active surface (3a) of the first lens (3) is a whole surface.
7. The method according to claim 1 or 2, wherein, In the manufacturing state of the lens system, the first lens (3) and the second lens (6) are oriented coaxially with each other.
8. The method according to claim 1, wherein, The first lens (3) is a biconvex lens.
9. The method according to claim 1 or 2, wherein, The second lens (6) is a biconcave lens.
10. The method according to claim 1 or 2, wherein, The recessed mold (4) is formed of polydimethylsiloxane.
11. The method according to claim 1 or 2, wherein, The contact between the first optical active surface (6a) of the second lens (6) and the first optical active surface (3a) of the first lens (3) is seamless.
12. A lens system comprising a first lens (3) formed of a first material having a first refractive index and a second lens (6) formed of a second material having a second refractive index, wherein, The first material and the second material, as well as the first refractive index and the second refractive index, are different. Its characteristics are, The lens system is an achromatic lens system manufactured by the method according to any one of claims 1 to 11.
13. A lens system comprising a plurality of lenses, wherein, At least two lenses are configured as an achromatic lens system, said achromatic lens system being manufactured by the method according to any one of claims 1 to 11.
14. A motor vehicle headlight, the motor vehicle headlight comprising an illumination device for generating and radiating light distribution, wherein, The lighting device has a lens system according to claim 12 or claim 13.