Glass Optical Element Cooling via Non-Contact Transport

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Solution Overview

Problem

Current methods for producing optical elements from glass, such as headlight lenses, face challenges in efficiently cooling these elements without damaging their optical surfaces, particularly during the cooling process where contact can occur, leading to potential damage and increased production costs.

Innovation Solution

A method involving a transport element made of steel, where the optical element is placed on a support surface outside the intended light path, and a controlled cooling path is used to cool the element without direct contact with the optical surfaces, utilizing a temperature gradient reversal process to ensure the glass is heated and cooled in a way that prevents surface damage, using a lance with coolant flow and heating devices to manage the glass's viscosity and temperature.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the optical element is cooled using conventional contact cooling methods, then the cooling efficiency is improved, but the optical surfaces may be damaged

Engineering Contradiction:

Improvecooling efficiencyVSAvoidoptical surface damage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

A transport element acts as an intermediary carrier between the press-molding process and the cooling path. The optical element is deposited on this transport element and transported through the cooling path without direct contact with cooling surfaces, thus preventing optical surface damage while maintaining efficient cooling through the intermediary structure

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces conventional mechanical contact cooling with a non-contact cooling approach. Instead of direct thermal contact between the optical element and cooling surfaces, the system uses radiant or convective cooling through a controlled atmosphere in the cooling path, eliminating mechanical contact that could damage optical surfaces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the optical element is handled and transported during cooling, then the cooling process can be controlled, but the risk of surface contact and damage increases

Engineering Contradiction:

Improvecooling controlVSAvoidsurface damage risk

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The transport element and cooling path are merged into an integrated system. The transport element carries the optical element through the entire cooling path, combining the functions of transport and cooling control into a single unified process that eliminates the need for separate handling operations that could cause surface damage

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transport element is designed with a specific surface structure that allows thermal energy transfer while protecting the optical element. The element may have regions with different thermal conductivities or surface properties that enable controlled cooling without direct damaging contact

Inventive Principle:

Principle #30Flexible shells and thin films

3Productivity

If the glass is rapidly cooled to increase production speed, then the productivity is improved, but the glass may crack or deform

Engineering Contradiction:

Improveproduction speedVSAvoidglass integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The cooling process is implemented in multiple stages or zones along the cooling path, with different cooling rates applied at different positions. This periodic or zoned cooling approach allows the glass to cool at controlled rates that prevent thermal shock and cracking while still achieving high overall production throughput

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The cooling parameters (temperature, cooling rate, atmosphere composition) are dynamically adjusted along the cooling path to match the thermal history requirements of the glass. This controlled parameter variation ensures the glass transitions through critical temperature ranges at appropriate rates to prevent deformation or cracking

Inventive Principle:

Principle #35Parameter changes

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 method effectively prevents damage to the optical surfaces during cooling, reduces production costs, and allows for the production of high-quality optical elements with precise temperature control, ensuring the glass is processed without surface contact, thus maintaining the optical integrity of the elements.

Implementation Method 1

passes through a cooling path without an optical surface of the optical element being touched

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 2

passes through a cooling path

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

utilizing a temperature gradient reversal process to ensure the glass is heated

Methodology Applied

Scientific EffectConduction: Conduction (thermal)

Data Source

PatentUS12157694B2Method of producing an optical element from glass

Publication Date: 2024.12.03 DOCTER OPTICS SE

AI summary

The invention relates to a method for producing an optical element from glass, wherein a portion of glass or a glass blank is blank-pressed, in particular on both sides, to form the optical element, wherein the optical element is then placed on a transport element and passes through a cooling path with the transport element, without the optical surface of the optical element being touched.