Vehicle Headlight Lens Press-Molding Process
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Solution Overview
Problem
The manufacturing of headlight lenses for vehicle headlights is costly, and existing methods require complex processes and additional post-treatment for contour finishing.
Innovation Solution
A method involving the press-molding of liquid transparent plastic material between a lower and upper mold under atmospheric air-pressure, without injection molding, where the plastic material is cooled and further material is added to form a lens element with a light dispersing surface structure, eliminating the need for vacuum or low-pressure pressing and subsequent contour finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection pressing/molding is used to manufacture headlight lenses, then manufacturing precision and automation are improved, but manufacturing costs and device complexity increase
Solution Approach 1:
The manufacturing process is divided into two separate pressing operations: first pressing to form the basic lens shape, and second pressing to create the final optical contour. This segmentation allows each pressing stage to focus on specific requirements, simplifying the overall process while maintaining precision.
Solution Approach 2:
The first pressing operation performs preliminary shaping of the lens blank before the final optical contour is formed. This preliminary action prepares the material in a controlled manner, reducing the complexity of the final pressing operation while ensuring precision.
2Ease of manufacture
If vacuum or low-pressure pressing is used, then manufacturing costs are reduced, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The pressing force is applied in two stages: the first pressing applies sufficient force to establish the basic shape, and the second pressing applies the necessary force for precise contour formation. This partial action approach ensures precision is achieved where needed without requiring excessive force throughout the entire process, maintaining cost-effectiveness.
3Manufacturing precision
If post-treatment for contour finishing is applied, then manufacturing precision is improved, but productivity and ease of manufacture worsen
Solution Approach 1:
The precise optical contour is formed during the second pressing operation itself, rather than requiring subsequent post-treatment. This preliminary action integrates the contour finishing into the manufacturing process, eliminating separate post-treatment steps and maintaining high productivity.
Solution Approach 2:
The pressing process itself creates the precise optical surface through controlled deformation of the plastic material between molded surfaces. The material and molding process work together to achieve the final precision contour without requiring additional service or treatment operations.
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 reduces manufacturing costs and simplifies the process by producing a headlight lens with a light dispersing surface structure, achieving a cost-effective and efficient production of vehicle headlight lenses with improved optical performance.
Implementation Method 1
the plastic material is cooled and further material is added to form a lens element
Implementation Method 2
liquid transparent, for example amorphous, plastic material is supplied or fed to a lower mold, wherein the plastic material is subsequently pressed
Data Source
AI summary
The invention relates to a method for producing an optical lens element, more particularly for illumination purposes, more particularly for producing a headlamp lens for a vehicle headlamp, more particularly for a motor vehicle headlamp, according to which method liquid, transparent, more particularly amorphous, synthetic material is placed into a lower mold. The synthetic material is then pressed between the lower mold and an upper mold by putting the lower mold and the upper mold together. The lower mold and the upper mold are then separated. Further liquid, transparent, more particularly amorphous, synthetic material is then added to the pressed synthetic material and the synthetic material is then pressed, more particularly precision pressed, to form the lens element.