Glass Optical Element Press Molding with Temperature Gradient
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing optical elements, such as headlight lenses, face challenges in achieving precise contour accuracy and hydrolytic resistance, particularly when using non-borosilicate glasses like soda lime glass, which require improved manufacturing processes to enhance weather resistance and optical properties.
Innovation Solution
A method involving the press molding of a glass blank with a controlled temperature gradient, using a protective cap and heating coils, followed by surface treatment with a specific agent to achieve hydrolytic resistance comparable to borosilicate glass, while maintaining cost-effectiveness and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-borosilicate glass (soda lime glass) is used for manufacturing optical elements, then manufacturing cost is reduced, but hydrolytic resistance and weather resistance deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the temperature gradient during press molding to achieve the desired balance between manufacturing cost and hydrolytic resistance. By optimizing the thermal parameters during the molding process, the invention enables the use of cost-effective soda lime glass while maintaining adequate weather resistance through precise temperature control during formation.
2Manufacturing precision
If press molding is applied to glass blanks, then manufacturing precision and contour accuracy are improved, but internal stresses increase
Solution Approach 1:
The patent controls the temperature gradient parameter during press molding to achieve optimal contour accuracy while minimizing internal stresses. By carefully managing the thermal parameters during the molding process, the invention resolves the contradiction between achieving high precision and avoiding excessive internal stress accumulation in the optical elements.
3Manufacturing precision
If higher heating temperatures are used during press molding, then glass flow and molding precision are improved, but energy consumption and risk of deformation increase
Solution Approach 1:
The patent optimizes the heating temperature parameter during press molding to achieve the necessary glass flow and molding precision while minimizing energy consumption. By carefully controlling the thermal parameters and using efficient heating methods, the invention achieves high molding precision without excessive energy input or risk of deformation.
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 method ensures high hydrolytic resistance and precise optical properties, reducing internal stresses and maintaining the optical tolerances of the headlight lenses, thus improving their performance and longevity.
Implementation Method 1
heated on the supporting body, in a cavity of a protective cap that is arranged in a furnace cavity, for example by means of heating coils, for example such that a temperature gradient is established in the blank in such a way that the blank is cooler inside than in and/or on the surface region
Implementation Method 2
The contact face is cooled by means of a cooling medium that flows through the supporting body
Data Source
AI summary
A method for manufacturing an optical element out of glass comprises placing a blank made of glass on an annular contact face of a supporting body having a hollow cross section. The blank is heated on the supporting body in a cavity of a protective cap that is arranged in a furnace cavity, such that a temperature gradient is established in the blank in such a way that the blank is cooler inside than on an outside region. The blank is press molded to form the optical element.