A method of repairing an automotive lamp assembly

Abstract

The application discloses a kind of automobile lampshade transparent component repair method, to solve the problems of insufficient strength, low matching accuracy and poor appearance of existing repair technology.The method comprises: after cleaning and evaluating damage, sticking aluminum foil as height reference outside broken residual part, and polishing to form flat base;Subsequently, according to the measured size, the transparent replacement part is processed by single-piece customization or batch replication, and the "temporary large blank" process can be used for small parts, and the adhesive surface of the parts to be painted is protected by adhesive tape for painting;Finally, the replacement part is aligned with the base, and the transparent adhesive is used for bonding and curing, and the edge recess is filled with reinforcement.The application realizes high strength, high precision and good optical effect of the repaired part, and has the ability to handle special needs and batch repair, significantly reducing maintenance cost.

Description

Technical Field

[0001] This invention relates to the field of automotive parts repair technology, and more specifically, to a method for repairing damaged automotive headlight covers. Background Technology

[0002] Automotive headlight components often break or break due to impacts, aging, or accidents. Traditional methods typically involve replacing the entire headlight assembly, which is costly, especially for high-end models. While some repair methods exist, such as plastic welding or universal adhesive, and involve purchasing a new headlight cover and removing the component for repair, these methods have the following significant drawbacks for headlight components where aesthetics are paramount: Repairing components by excavation: Excavation and filling result in a waste of new lampshade resources, and the installation of components requires drilling holes, which poses a significant safety risk. For stressed components, there is a risk of water leakage.

[0003] Poor aesthetics: Ordinary adhesive bonding or welding will produce obvious glue marks and weld lines, which seriously affect light transmission and appearance.

[0004] Insufficient strength: Simple butt bonding has a small contact area, making it prone to cracking again after being subjected to stress.

[0005] Low matching accuracy: The size and contour of the repaired part are difficult to match precisely with the original remnant, which may lead to installation difficulties or misalignment.

[0006] Unable to handle special requirements: There is a lack of effective process flow for parts that require surface coloring (painting) or are small and difficult to handle.

[0007] Therefore, there is a need for a dedicated repair method that is low-cost, can achieve high-precision matching, high structural strength, and can maintain a good appearance and scalability. Summary of the Invention

[0008] The purpose of this invention is to overcome at least one of the shortcomings of existing technologies and provide a method for repairing transparent components of automotive headlight covers. This method achieves seamless, high-strength, and aesthetically pleasing repairs by creatively processing the fractured base and customizing replacement parts, and can flexibly meet the needs of painting, micro-part processing, and mass production.

[0009] To achieve the above objectives, the technical solution provided by the present invention is as follows: A method for repairing a transparent component on an automotive headlight cover includes the following steps: S1. Damage Assessment and Cleaning: Thoroughly clean the fracture area, remove oil and dust, and assess the integrity of the fracture surface to confirm repairability.

[0010] S2. Dimension Determination: Use calipers, gauges and other tools to accurately measure the key dimensions of the broken part (i.e. the missing part), such as its length, width, height, thickness and outline shape.

[0011] S3. Base Preparation: This is the core preparatory step. Apply a ring of masking material (preferably aluminum foil tape) around the bottom perimeter of the broken component as a height reference. Then, carefully use a polishing tool (such as sandpaper or a grinder) to smooth the fracture surface of the broken component into a flat, clean "base" plane. The height of this plane should be flush with the top surface of the applied masking material. This ensures the flatness and levelness of the subsequent bonding surfaces.

[0012] S4. Customized Replacement Part Manufacturing: Based on the dimensions measured in S2, prepare a transparent replacement part that perfectly matches the measurements. This step can be implemented in two ways: Method A (Single-piece Customization): Cut blanks from transparent or non-transparent plastic sheets such as acrylic, polycarbonate, and discarded lampshades. For complex shapes, multiple blanks can be spliced ​​together to form a composite blank. Then, finely sand the edges of the blank to ensure its contour and dimensions perfectly match the broken part. The thickness of the bonding surface of the replacement part must match the thickness of the broken surface at the base, and its bottom edge should be sanded with rounded or beveled transition surfaces to increase the bonding area and aesthetics. For small parts, the blanks can be cut into temporary blanks larger than the final size for splicing and fixing. After stabilization, they can be uniformly sanded to the design size for ease of operation. For parts requiring painting, before bonding, fix the bonding end face upright on a flat sheet of adhesive tape (such as masking tape), paint the exposed surface, and remove it after completion, ensuring the bonding surface is clean.

[0013] Method B (Batch Replication): When multiple identical replacement parts are needed, a mold replication method can be used. Use the original component or a repaired component as a master mold, and create a female mold using curable silicone. Cover the mold with aluminum foil to form an overflow groove. Then, pour transparent epoxy resin or UV adhesive into the mold and cure it at a controlled temperature (e.g., heating lamp, curing lamp, constant temperature chamber). After demolding, multiple identical replacement parts can be obtained.

[0014] S5. Post-processing: Remove the masking material used as a reference at the base and carefully clean any remaining adhesive or sanding debris from the base surface to ensure that the bonding surface is absolutely clean.

[0015] S6. Bonding and Curing: Before bonding the replacement part to the base contour end face, soak the replacement part in transparent adhesive to complete the polishing treatment. Soaking in adhesive allows the adhesive to fill the surface of the replacement part, making the matte replacement part smooth and transparent. For transparent components, no additional polishing is required after bonding, greatly improving efficiency and avoiding damage to other parts of the lampshade during subsequent sanding. After polishing, apply transparent fast-drying adhesive (such as cyanoacrylate adhesive) or transparent structural adhesive to a clean base surface. Precisely align the processed replacement part with the base contour and bond it. For replacement parts with rounded / beveled bottom corners, after bonding, fill the recess at the joint between the replacement part and the base with UV structural adhesive to enhance sealing and strength. Then perform UV curing until the adhesive is completely cured. The beneficial effects of this application are:

[0016] High precision and reliable strength in repair: The process of "attaching reference datum → grinding the base flat" creates an ideal bonding plane; the customized replacement parts can achieve micro-scale matching, and combined with edge reinforcement treatment, the mechanical strength of the repaired part is close to that of the original part.

[0017] Highly operable and widely applicable: The proposed "temporary large blank" strategy solves the operational challenges of micro-sized parts; the mold replication method provides an efficient solution for batch repair. The entire process is clearly defined, with relatively standard tool requirements, making it suitable for professional repair shops.

[0018] Significant cost-effectiveness: It avoids the expensive cost of replacing the entire lampshade assembly, achieving high-quality repairs with only lower material and labor costs, resulting in outstanding economic benefits.

[0019] Before bonding the replacement part to the contoured end face of the base, the replacement part is first soaked in transparent adhesive to complete the polishing process. Soaking in the adhesive allows it to fill the surface of the replacement part, making the matte replacement part smooth and transparent. For transparent components, there is no need for the tedious process of additional masking and spraying after bonding, greatly improving efficiency and avoiding damage to other parts of the lampshade during subsequent sanding. Attached Figure Description

[0020] Figure 1 This is a photograph of the broken fragment remaining on the lampshade. Figure 2 This is a three-dimensional schematic diagram of the protrusion of the fractured residual part on the lampshade in this application; Figure 3 The images show the fractured part and the fractured residue in this application. Figure 4 This is a physical image of the base of this application. Figure 5 This is a three-dimensional schematic diagram of the masking tape being applied during the base treatment in this application; Figure 6This is a three-dimensional schematic diagram showing that the height of the base is flush with the height of the shielding material in the base treatment of this application; Figure 7 This is a photograph of the assembled blanks that are pasted together. Figure 8 A photograph of the actual workpiece being ground to form the composite blank. Figure 9 A comparison image of the replacement part and the broken part; Figure 10 The bottom edge of the replacement part has been polished to form a rounded or beveled transition surface; Figure 11 This is a schematic diagram showing the bonding of the replacement part to the base; Figure 12 This is a schematic diagram of the replacement part being painted upright. Figure 13 A diagram illustrating the quick varnishing process for replacement parts.

[0021] Label Explanation: 1. Fractured part; 2. Fractured residue; 3. Base; 4. Shielding material (aluminum foil tape); 5. Replacement part; 51. Assembled blank; 6. Lampshade. Detailed Implementation

[0022] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal," etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. These terms are primarily for better description of this application and its embodiments and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to be constructed and operated in a specific orientation. Furthermore, some of the above terms may be used to indicate other meanings besides orientation or positional relationships; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application according to the specific circumstances. Example 1: Repair of a broken car headlight cover and the transparent component supporting the bumper.

[0023] S1, Assessment and Cleaning (e.g.) Figures 1-3 (As shown): Observe the broken part 1 of the decorative strip and confirm that there are no missing fragments. Clean the broken area with alcohol.

[0024] S2. Determine the dimensions: Use calipers to measure the length (15mm), width (5mm), and thickness (2mm) of the broken part 1. If the broken part 1 is lost, the dimensions of the broken part 1 can be obtained by measuring the same lamp assembly (broken part 1) on other identical models.

[0025] S3, base 3 treatment (such as...) Figures 4-6 As shown): On the bottom periphery of the remaining broken part 2, a ring of aluminum foil tape 4 about 5mm wide is tightly attached. The remaining broken part is initially smoothed using an electric grinder, and then the fracture surface is gradually and carefully sanded with 180-400 grit sandpaper until the sanded surface is completely flush with the upper edge of the aluminum foil tape 4, forming a smooth base 3.

[0026] S4, Replacement Part 5 Custom Processing (Single Piece, Miniature Part) (e.g.) Figures 7-10 ): (1) Cut a “temporary large blank” about 20mm long and 8mm wide from a 2mm thick transparent polycarbonate plate (the size is slightly larger than the design value so that it can be held by hand).

[0027] (2) Fix the assembled blank 51 (also called "temporary large blank") temporarily with a clamp, and roughly grind out its basic outline according to the original shape. When assembling the temporary large blank, the mounting surfaces need to be accurately aligned to ensure the accuracy of the inner dimensions of the temporary large blank, while the outer dimensions can be slightly larger.

[0028] (3) Then, compare it with the base 3 multiple times and polish it finely until its length, width, outline and missing parts are completely matched, and the bottom adhesive surface is perfectly attached to the base 3. Finally, polish the bottom edge to make a 0.5mm bevel.

[0029] S5. Post-processing: Carefully peel off the aluminum foil tape 4 around the base 3, and clean the surface of the base 3 with a cotton swab dipped in alcohol.

[0030] S6: Adhesion curing (e.g.) Figure 11 As shown below: Apply UV adhesive to one end of a small object such as a toothpick, and press it against the bottom of replacement part 5. Then, holding the other end of the small object, immerse the entire replacement part in the adhesive. After removing it, use UV light to quickly fix it and complete the varnishing process. After varnishing, apply a thin layer of transparent quick-drying adhesive to the bottom surface of replacement part 5, align it with the base, and gently press it to adhere, completing the bonding and curing process.

[0031] In the V-shaped groove formed by the bevel of replacement part 5 and base 3, apply a small amount of UV structural adhesive to fill it (a small amount of adhesive can be applied to the V-shaped groove using a toothpick or a syringe, or applied in sections). Allow it to stand for 24 hours or expose it to ultraviolet light to allow the adhesive to fully cure. After the repair is completed, both the appearance and structure are restored to good condition. Example 2: Repair and color a broken non-transparent bumper support component on a headlight cover (painting required).

[0032] like Figure 12 As shown, S1 to S4: Perform steps 1 to 4 of Example 1 to produce a transparent replacement part 5 that matches the broken lampshade. Its bottom is rounded. Add the following step in step S4: (1) Spray painting: Take a piece of strong masking tape, with the adhesive side facing up, and stick it flat on the work surface. Press the bottom end of the replacement part 5 that needs to be bonded firmly and upright onto the adhesive side of the tape. Ensure that the replacement part 5 is upright and does not tip over.

[0033] (2) Spray paint on the exposed surface (i.e., the surface that will be visible in the future) of the fixed replacement part 5 with paint that matches the color of the headlights. Let it dry after spraying.

[0034] (3) After the paint is completely dry, remove the replacement part 5 from the masking tape. At this point, its bonding end is protected by the tape, free of any paint, and remains clean and has optimal adhesion.

[0035] S5-S6: Perform steps 5 and 6 in Example 1 to complete the cleaning and final bonding and curing of base 3. The repaired headlight eyebrows are the same color as the original vehicle and are firmly bonded. Example 3: Batch repair of 6 clips for damaged corner light covers of multiple identical vehicle models

[0036] (1) Obtain a replacement part 5 as the master mold.

[0037] (2) Making silicone mold: Place the master mold in a container, pour in liquid silicone to completely cover the master mold, let it stand and solidify, and then remove the master mold to obtain the silicone female mold of the buckle.

[0038] (3) Prepare the mold: Wrap several layers of aluminum foil tightly around the outside of the silicone mold to form a barrier slightly larger than the mold, leaving space at the top and bottom as overflow channels.

[0039] (4) Casting replication: Slowly inject the prepared transparent epoxy resin into the mold cavity until it is full and slightly overflows into the overflow groove.

[0040] (5) Controlled curing: Place the entire mold in a constant temperature oven at 40°C and heat for 2 hours to accelerate curing.

[0041] (6) Demolding: After curing, remove the replicated transparent snap-fit ​​replacement part 5 from the silicone mold. Repeat steps 4-6 to quickly produce multiple identical replacement parts 5.

[0042] (7) For each lampshade 6 to be repaired, perform steps 1-3 (base 3 treatment), step 5 (post-treatment) and step 6 (bonding and curing) in Example 1 respectively, and complete the repair using the batch-made replacement parts 5.

[0043] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A method for repairing components on an automotive lamp cover, characterized in that, Includes the following steps: S1. Damage assessment and cleaning: Clean the fractured component area and assess the integrity of the fracture surface; S2. Determine the dimensions: Obtain the dimensions of the fractured component (1); S3, Base (3) treatment: Attach masking material (4) along the outside of the fractured residual part (2) as a height reference, grind the fractured residual part (2) to form a flat base (3), so that the height of the base (3) is flush with the height of the masking material (4); S4. Customized processing of replacement part (5): Based on the measured dimensions, prepare a replacement part (5) that matches the broken part (1); S5. Post-processing: Remove all or part of the covering material (4) to expose the base (3) and clean up any excess adhesive; S6. Bonding and curing: Align the replacement part (5) with the contour end face of the base (3), bond and cure.

2. The method for repairing automotive lamp cover components according to claim 1, characterized in that, In the base (3) processing (S3), the shielding material (4) is aluminum foil, which is pasted around the bottom of the part.

3. The method for repairing automotive lamp cover components according to claim 1, characterized in that, In the customized processing (S4) of the replacement part (5), the preparation of a single replacement part (5) includes: Cut blanks from plastic sheets, or assemble multiple blanks to form composite blanks (51); Grind the edges of the blank or composite blank (51) to match its dimensions with those of the broken piece (1); The bonding surface of the replacement part (5) is adapted to the thickness of the fracture surface, and its bottom edge is polished to form a rounded or beveled transition surface.

4. The method for repairing automotive lamp cover components according to claim 3, characterized in that, When the size of the replacement part (5) is small, each of the blanks is first cut into temporary blanks larger than the final required size and spliced ​​and temporarily fixed; after the spliced ​​structure is stable, the excess parts on all temporary blanks are removed by grinding to achieve the design size.

5. The method for repairing automotive lamp cover components according to claim 3, characterized in that, Prior to the bonding and curing (S6) step, a step of painting the outer surface of the replacement part (5) is also included: The adhesive end face of the replacement part (5) is vertically pasted onto the adhesive surface of the flat and fixed tape. The exposed surface is sprayed with paint. After the treatment is completed, it is removed to obtain a clean, painted replacement part (5) with a clean adhesive surface.

6. The method for repairing automotive lamp cover components according to claim 3, characterized in that, Before the replacement part (5) is aligned and bonded to the contour end face of the base (3), the replacement part is first soaked in transparent glue to complete the varnishing process.

7. The method for repairing automotive lamp cover components according to claim 1, characterized in that, In the customized processing (S4) of the replacement part (5), the replacement part (5) is prepared in batches, including: Use curable silicone to create a mold based on the original components; Resin glue is filled into the mold and cured at a controlled temperature to form multiple replacement parts (5).

8. The method for repairing automotive lamp cover components according to claim 6, characterized in that, An aluminum foil is wrapped around the outside of the mold to create an overflow space for the adhesive.

9. The method for repairing an automotive lamp cover assembly according to claim 3 or 6, characterized in that, The bonding and curing (S6) is performed using a fast-drying adhesive; when the replacement part (5) has a rounded or beveled transition surface, adhesive is used to fill the recess formed at the edge of the contact surface between the base (3) and the replacement part (5) to enhance the structure.

10. The method for repairing an automotive lamp cover assembly according to claim 3, characterized in that, Based on the bottom edge of the replacement part (5) being ground to form a rounded or beveled transition surface, in the bonding and curing (S6) step, the recess formed at the edge of the contact surface between the base (3) and the replacement part (5) is filled with cured adhesive.

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