Headlight Optical Element Mould With Exchangeable Cut-Off Inserts
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Solution Overview
Problem
The existing methods for manufacturing headlights with integrated cut-off line shades are complicated and expensive due to the need for multiple molds to accommodate different cut-off line shapes and legal requirements across various regions and vehicle models.
Innovation Solution
A mould for injection moulding of optical elements with a cavity that includes a shade-forming section and exchangeable inserts to define the cut-off line shape, allowing the same mould to produce different cut-off line shades by changing only the insert.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate shade component is used to block light and create a cut-off line, then the desired low-beam light pattern is achieved, but the manufacture of the headlight becomes complicated and expensive due to individual mounting requirements
Solution Approach 1:
The patent merges the shade component with the reflector or lens holder into a single integrated optical element. The shade is formed as an integral part of the reflector during injection molding, eliminating the need for separate manufacturing and mounting steps. This combining approach maintains the light-blocking function while significantly simplifying the manufacturing process.
2Ease of manufacture
If the shade is moulded together with other headlight components, then manufacturing is simplified, but a different mould is necessary for each different type of cut-off line, increasing production costs
Solution Approach 1:
The patent segments the mold into two functional parts: a permanent base mold that forms the main optical element (reflector/lens holder), and interchangeable inserts that define the specific cut-off line shape. The insert can be removed and replaced with another insert having a different geometry to produce different cut-off line patterns, while the base mold remains unchanged.
Solution Approach 2:
The base mold is designed with a universal shade-forming section that can accommodate multiple different inserts. This allows a single base mold to produce various optical elements with different cut-off line configurations by simply changing the insert, making the manufacturing system adaptable to different regional requirements and vehicle models.
3Adaptability or versatility
If multiple moulds are produced to accommodate different cut-off line shapes and legal requirements, then all regional and vehicle-specific requirements are met, but production costs and storage space requirements increase significantly
Solution Approach 1:
The patent divides the molding system into a permanent base mold and replaceable inserts. Each insert is designed with specific geometry to create different cut-off line shapes required by various countries and vehicle models. This segmentation allows one base mold to replace multiple complete molds, reducing the total number of molds from many to just one base mold plus several small inserts.
Solution Approach 2:
The patent extracts the variable geometric feature (cut-off line shape) from the main mold structure and places it in a separate, removable insert. This extraction allows the essential base mold to remain unchanged while only the small, easy-to-store insert needs to be changed to produce different optical element variants.
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 reduces production costs and simplifies the manufacturing process by enabling the use of a single mould for multiple cut-off line shapes, saving storage space and allowing faster adjustments to different legal and aesthetic requirements.
Implementation Method 1
Mould for injection moulding of an optical element for a headlight
Data Source
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AI summary
Mould (1) and method for injection moulding of an optical element (2) for a headlight, especially for low beam light. The mould (1) has a cavity (4) for forming the optical element (2) which comprises a shade-forming section (5) for moulding a cut-off line shade (6). The mould (1) comprises an insert (7) for limiting the shade-forming section (5) according to a required cut-off line shape, wherein the insert (7) is at least partially insertable into the shade-forming section (5).