Press-molded Headlight Lens with Periodic Surface Modulation
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Solution Overview
Problem
Headlight lenses face stringent design criteria regarding optical properties and light-related standard values, particularly in achieving optimal bright-dark boundary gradients and glare values, which existing technologies have not adequately addressed.
Innovation Solution
A headlight lens with a modulation comprising periodic waves on its light entry and/or exit faces, made of transparent materials like glass, featuring interdigitating waves with specific amplitude and phase shifts, allowing for press-molding without subsequent polishing, to create a surface that optimizes light distribution and adheres to stringent light-related standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional headlight lenses without modulation are used, then manufacturing is simpler, but light distribution quality and adherence to light-related standards deteriorate
Solution Approach 1:
The modulation is press-molded directly into the lens during the molding process, preparing the precise surface structure in advance. This preliminary action eliminates the need for subsequent polishing or finishing operations, as the modulation is created in one step during manufacturing, thereby achieving high light distribution quality without proportionally increasing manufacturing complexity
Solution Approach 2:
The invention changes the surface parameters of the lens by introducing periodic modulations with specific amplitudes and wavelengths. These parameter changes optimize the light distribution characteristics and adherence to light-related standards, while the press-molding process ensures these complex surface parameters are achieved efficiently during manufacturing
2Productivity
If traditional lens surfaces without modulation are used, then production is faster, but optical performance and glare control worsen
Solution Approach 1:
The invention merges the modulation creation step with the lens molding process itself. By integrating the formation of periodic modulations into the press-molding operation, the patent eliminates separate finishing operations, thereby maintaining high production speed while achieving superior optical performance through the precisely controlled modulation structures
3Manufacturing precision
If modulation with periodic waves is added to the lens, then light distribution and glare control improve, but manufacturing complexity increases
Solution Approach 1:
The invention replaces complex mechanical finishing operations with a press-molding process that directly creates the modulation structures. This substitution eliminates the need for subsequent mechanical polishing or cutting operations, thereby achieving precise glare control through modulation while maintaining manufacturing simplicity through the efficiency of the press-molding process
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 enables the manufacture of headlight lenses that meet stringent light-related standards, such as reduced glare and optimal bright-dark boundary gradients, while being cost-effective and maintaining a fringe-free light distribution.
Implementation Method 1
the modulation comprises a plurality of (periodic) waves... wherein the deflection and/or amplitude of each one of the plurality of waves extends in parallel to the (contour of) the surface on which the modulation is formed
Data Source
AI summary
The present disclosure relates to a headlight lens for a vehicle headlight, for example a motor vehicle headlight, said headlight lens comprising a press-molded lens member and an optically effective surface, the surface having a modulation with a wave of which the amplitude runs along the surface of the headlight lens.