Fresnel Projection Lens Customization for Multi-Shape Headlights
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Solution Overview
Problem
The production of projection lenses for headlamps requires separate tools for each different shape, leading to high costs due to the need for multiple molds, which is inefficient and costly.
Innovation Solution
A method involving the production of identical Fresnel lenses that are then altered in size and/or shape to fit specific headlamp modules, using techniques like cutting, laser beams, or stamping, allowing for the production of multiple lenses with a single tool, reducing tooling costs and enabling quicker adaptation to different shapes and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate injection molding tools are used for each projection lens shape, then manufacturing precision and lens quality are maintained, but production costs increase significantly due to multiple expensive molds
Solution Approach 1:
The projection lens is divided into two functional segments: a standardized Fresnel lens base (produced via injection molding) and a custom optical element (produced via glass molding). This segmentation allows the expensive custom shaping to be applied only to the critical optical portion while the base remains standardized and cost-effective.
Solution Approach 2:
The patent merges two different manufacturing approaches by combining the injection-molded Fresnel lens base with a separately molded glass optical element. The Fresnel structure is produced through injection molding while the custom-shaped optical portion is produced through glass molding, then they are integrated into a single functional lens assembly.
2Adaptability or versatility
If multiple injection molding tools are used for different projection lens shapes, then various headlamp module requirements are met, but device complexity and tooling requirements increase
Solution Approach 1:
A single standardized Fresnel lens base design serves multiple functions across different headlamp modules. The universal base can be combined with different custom optical elements to produce various projection lens shapes, eliminating the need for separate injection molding tools for each application.
Solution Approach 2:
Customization is applied locally only to the optical element portion that requires shape variation, while the Fresnel lens base remains standardized. This allows different headlamp module requirements to be met through localized customization rather than complete redesign of the entire lens.
3Ease of manufacture
If a single injection molding tool is used for all projection lenses, then tooling costs are reduced, but the ability to produce different shapes and sizes is limited
Solution Approach 1:
The lens design segments the standardized Fresnel base (produced by the single injection molding tool) from the custom optical element (produced by glass molding). This allows a single tool to produce the base while different optical elements provide the shape variety needed for various applications.
Solution Approach 2:
The projection lens uses a composite structure combining a plastic Fresnel lens base with a glass optical element. This composite approach allows the injection molding process to produce the base while glass molding creates the custom-shaped optical portion, achieving both cost efficiency and shape diversity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production costs and tooling requirements while enabling rapid customization of Fresnel lenses for various headlamp modules, facilitating the production of multiple lenses with diverse dimensions and shapes efficiently.
Implementation Method 1
The projection lens can have at least one substrate made of a transparent material, which has a Fresnel structure with numerous coaxial circular steps
Implementation Method 2
The projection lens is configured to convert an expanded light distribution generated by a primary lens in the headlamp into a light distribution corresponding to the initial light distribution obtained with the headlamp
Data Source
AI summary
A method is provided for producing numerous projection lenses for numerous headlamps for motor vehicles. Each projection lens is configured to convert an expanded light distribution generated by a primary lens in the headlamp into a light distribution corresponding to the initial light distribution obtained with the headlamp. Each projection lens comprises a Fresnel lens. Numerous identical Fresnel lenses are produced forming the initial Fresnel lenses. The size and/or shape of one of these initial Fresnel lenses is altered to obtain a first Fresnel lens that can be incorporated in a first headlamp. The size and/or shape of a second initial Fresnel lens is altered to obtain a second Fresnel lens that can be incorporated in a second headlamp that has a different size and/or shape than the first Fresnel lens.