Glass Headlight Lens Surface Layer for Optical Attractiveness
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Solution Overview
Problem
Current headlight lenses for motor vehicles face challenges in achieving both optical attractiveness and high photometric performance while maintaining low costs, with existing solutions either being costly or compromising on optical appearance.
Innovation Solution
A headlight lens made of glass with a transparent lens body featuring a surface with a higher aluminum concentration and lower sodium concentration than the lens body, which is blank molded and treated with a gas overflow process to form a layer with enhanced optical properties, including a convex curvature and specific chemical compositions to optimize light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mechanical polishing is used to achieve optical attractiveness, then the lens appearance is improved, but production costs and complexity increase
Solution Approach 1:
The patent replaces mechanical polishing with a chemical treatment process using an alkaline polishing bath containing potassium hydroxide and/or sodium hydroxide. This chemical substitution eliminates complex mechanical polishing equipment while achieving the desired optical surface quality through chemical etching that creates a smooth, light-scattering surface layer.
2Illumination intensity
If chemical polishing with sulphuric acid-hydrofluoric acid mixture is used, then optical appearance is improved, but production costs increase significantly
Solution Approach 1:
The patent changes the chemical parameters of the polishing bath by using alkaline substances (potassium hydroxide and/or sodium hydroxide) with concentrations of 5-50% instead of the conventional sulphuric acid-hydrofluoric acid mixture. This parameter change reduces production costs while achieving comparable or superior optical appearance through controlled chemical etching that creates a uniform surface layer.
3Ease of manufacture
If glass composition is modified to reduce aluminum and increase sodium, then production costs decrease, but optical performance deteriorates
Solution Approach 1:
The patent applies local quality by creating a surface layer with modified chemical composition through controlled etching in the alkaline polishing bath. The surface layer develops different properties (reduced aluminum, increased sodium) compared to the bulk glass, with thickness controlled at 0.5-5 μm. This localized modification achieves cost reduction through simplified glass composition while maintaining optical performance through the specially treated surface layer.
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
The solution results in a headlight lens that offers improved optical attractiveness, high brilliance, and efficient light distribution with a significant reduction in production costs, ensuring a high percentage of light is directed into the principal illumination area while minimizing light in sub-illumination areas.
Implementation Method 1
a polishing bath comprising an alkaline substance, in particular potassium hydroxide and/or sodium hydroxide, wherein the potassium hydroxide has a concentration of 5-50 % and the sodium hydroxide has a concentration of 5-50 %
Data Source
AI summary
The invention relates to a headlight lens for a vehicle headlight comprising a light source, particularly for a motor vehicle headlight, wherein the headlight lens comprises a transparent lens body made of glass comprising a surface arranged to face the light source and a surface arranged to face away from the light source, and wherein the headlight lens comprises at least with respect to said surface arranged to face away from the light source a layer comprising an aluminum concentration which is higher than an aluminum concentration inside the lens body and/or a sodium concentration which is lower than a sodium concentration inside the lens body.