Projection Lens Thick Part for Resin Filling Pressure
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Solution Overview
Problem
The existing process for manufacturing projection lenses using a vehicle lamp's projection lens is hindered by a thin gate that leads to increased pressure loss and reduced moldability, resulting in decreased productivity and increased costs due to insufficient filling pressure and quality issues.
Innovation Solution
A projection lens design with a thick peripheral edge portion and a gate mark on its outer surface, allowing for a larger gate sectional area and improved resin flow, which enhances filling pressure and moldability, and incorporates a thick part that protrudes towards the incidence part to utilize dead light distribution areas effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gate is made thin to match the thin peripheral edge portion, then the projection lens can be molded with accurate dimensions, but the pressure loss in the gate increases and filling pressure becomes insufficient
Solution Approach 1:
The peripheral edge portion is designed with local thickness variation: a thin section for dimensional accuracy and a locally thickened section (protrusion) for adequate gate flow area. This allows the gate to communicate with a thicker region, maintaining sufficient filling pressure while the overall peripheral edge remains thin for precision molding.
2Device complexity
If the gate sectional area is reduced to match the thin peripheral edge, then the molding process can be simplified, but the pressure loss increases and productivity decreases
Solution Approach 1:
By introducing a localized thick protrusion at the peripheral edge, the gate can be positioned to communicate with this thicker region, maintaining a larger gate sectional area for reduced pressure loss and improved productivity, while the rest of the peripheral edge remains thin for accurate molding.
3Shape
If the peripheral edge portion is kept thin throughout, then the boundary between incidence and emission parts is well-defined, but the gate becomes thin and moldability deteriorates
Solution Approach 1:
The peripheral edge portion incorporates a localized thick protrusion that provides adequate thickness for gate communication and molding, while the overall boundary between incidence and emission parts remains well-defined and thin, achieving both good moldability and clear boundary definition.
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 design improves size precision and quality while reducing manufacturing costs by ensuring sufficient filling pressure and increasing productivity, and enhances the appearance of the vehicle lamp by refracting light effectively and hiding internal structures.
Implementation Method 1
a projection lens configured to emit light of a light source incident on an incidence part from an emission part
Data Source
AI summary
A projection lens formed of a light-transmitting resin including an incidence part on which light is incident, an emission part, a peripheral edge portion, and a thick part. Light is incident on the incidence part. The emission part emits the light incident from the incidence part. The peripheral edge portion is provided at a boundary between the incidence part and the emission part. The thick part is provided at a part of the peripheral edge portion, made thicker in an optical axis direction than other parts of the peripheral edge portion and having a gate mark formed at least on a part of an outer peripheral surface of the thick part.