Headlight Lens Surface Molding After Localized Reheating

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Solution Overview

Problem

Existing methods for manufacturing optical lens elements, such as headlight lenses, face challenges in achieving precise control over the formation of optically effective surfaces, particularly in terms of depth and surface roughness, which affects the quality and functionality of the final product.

Innovation Solution

A method involving injection molding of a pre-lens element using amorphous plastic, followed by controlled cooling and localized heating of the optically effective surface to a depth of up to 1000 micrometers, allowing the pre-lens element to be pressed into a final contour mold for precise shaping, including the formation of diffractive optics and light-scattering surface structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the pre-lens element is cooled completely to solidify the plastic, then the structural stability is improved, but the ability to form precise optically effective surfaces is worsened

Engineering Contradiction:

Improvestructural stabilityVSAvoidprecision of optically effective surfaces

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent applies local quality by differentiating the thermal state of the pre-lens element: the bulk material is completely solidified for structural stability, while the surface layer (0-1000 micrometers) is locally reheated to make it moldable for precise optical surface formation. This allows simultaneous achievement of structural stability and surface precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the plastic material into two distinct thermal zones: a solidified bulk region providing structural support and a superficial moldable layer enabling precision optical surface formation. This segmentation allows independent optimization of each region's properties.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If the plastic is heated to make the surface moldable, then the manufacturing precision of optically effective surfaces is improved, but the structural stability is worsened

Engineering Contradiction:

Improveprecision of optically effective surfacesVSAvoidstructural stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The heating process is localized to only the surface layer (0-1000 micrometers) rather than the entire pre-lens element. This local quality approach ensures that only the surface requires moldability, while the bulk remains structurally stable and solidified.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent applies partial action by heating only the necessary surface portion (0-1000 micrometers) rather than the entire component. This partial heating provides sufficient moldability for optical surface formation without excessively heating the bulk material that would compromise structural stability.

Inventive Principle:

Principle #16Partial or excessive action

3Ease of manufacture

If the heating depth is increased to ensure complete moldability, then the ease of manufacture is improved, but the manufacturing precision is worsened due to excessive heat affecting the bulk

Engineering Contradiction:

Improveease of surface moldingVSAvoidprecision of optically effective surfaces

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent optimizes the heating parameter (depth) to a specific range (0-1000 micrometers) that balances moldability and precision. This parameter change ensures the surface is sufficiently heated for easy molding while preventing excessive heat penetration that would compromise bulk structural integrity and surface precision.

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 approach enables the production of optical lens elements with high precision and accuracy in optically effective surfaces, enhancing the performance and functionality of vehicle headlight lenses, particularly in implementing matrix light and adaptive high beam technologies.

Implementation Method 1

the pre-lens element being cooled in such a way that the plastic solidifies

Methodology Applied

Scientific EffectSolidification: Phase Change

Implementation Method 2

at least one optically effective surface of the pre-lens element then being heated in such a way that the plastic is moldable on the optically effective surface

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS12552116B2Method of manufacturing a lens element

Publication Date: 2026.02.17 HELLA GMBH & CO KGAA

AI summary

The invention concerns a method for producing an optical lens element, in particular for illumination purposes, in particular for producing a headlight lens for a vehicle headlight, in particular for a motor vehicle headlight (10), wherein a pre-lens element (42, 43) is injection molded using at least one mold by heating liquefied transparent plastic, wherein the pre-lens element (42, 43) being cooled in such a way that the plastic solidifies, and at least one optically effective surface of the pre-lens element (42, 43) then being heated in such a way that the plastic on the optically effective surface can be shaped, in particular up to a depth of not more than 1000 micrometers, wherein the pre-lens element (42, 43) is pressed with the optically effective surface in a final contour mold to form the lens element.