Patent Grant
12325161
The disclosure relates to a method for producing an optical element having at least one optically effective surface, wherein the optically effective surface comprises a contour and a surface structure superimposed on the contour,
Such a so-called multi-cavity process is disclosed, for example, in WO 2014/161014 A1, DE 10 2015 012 324 B4 and WO 2019/179571 A1. For example, WO 2014/161014 A1 discloses a method for producing an injection-molded part, for example an optical element, wherein an injection molding compound is molded at at least two injection stations by means of at least two injection operations, wherein a pre-injection molded part produced in one of the at least two injection operations is cooled in a cooling station between the at least two injection operations. The aim of the multi-cavity process is to select the layer thicknesses in such a way that the cycle time is optimally short (see for example DE 10 2008 034 153 B4).
The present disclosure relates for example to a method for producing an optical element having at least one optically effective surface, wherein the optically effective surface comprises a contour and a surface structure superimposed on the contour, wherein for example it is provided that liquid transparent plastic is injection molded by means of a (smooth) injection mold of an injection molding machine in dependence on a group of injection molding parameters to form an injection molded component having the contour of the optically effective surface without a surface structure superimposed on the contour, wherein thereafter at least one parameter from the group of injection molding parameters is set and/or corrected in dependence on properties of the injection molded component.
The present disclosure relates to a method for producing an optical element having at least one optically effective surface according to claim 1 and according to claim 9, wherein the optically effective surface comprises a contour and a surface structure superimposed on the contour, wherein for example it is provided that liquid transparent plastic is injection molded by means of a (smooth) injection mold of an injection molding machine in dependence on a group of injection molding parameters to form an injection molded component having the contour of the optically effective surface without a surface structure superimposed on the contour, wherein thereafter at least one parameter from the group of injection molding parameters is set and/or corrected in dependence on properties of the injection molded component, and wherein thereafter the optical element with liquid transparent plastic is injection molded using the group of (set and/or corrected) injection molding parameters. For example, it is provided that during injection molding a further injection mold corresponding to the (smooth) injection mold is used, by means of which the surface structure or the contour is molded or formed in connection with the surface structure.
The disclosure further relates to a method of producing an optical element having at least one optically effective surface, wherein the optically effective surface comprises a contour and may comprise or comprises a surface structure superimposed on the contour,
For example, it is provided that in the method of producing an optical element having at least one optically effective surface which comprises a contour and may comprise a surface structure superimposed on the contour, it is provided that
If the method is intended to produce an optical element having a first optically effective surface and a second optically effective surface, it may be provided that the second injection molding step is followed by a third injection molding step,
Alternatively, however, the or an optical element produced in a first injection molding step and a second injection molding step may include a first optically effective surface and a second optically effective surface.
In an embodiment, in the third injection molding step, the injection mold may be replaced by a smooth injection mold and a test element may be produced by means of the smooth injection mold, which is a smooth injection mold corresponding to the injection mold in the third injection molding step. Based on the properties of the test element produced in the third injection molding step, at least one parameter of the third injection molding step may then be set and/or corrected, so that further pre-injection molded components and/or pre-injection molded parts with at least one pre-injection molded component are injection molded into the optical element by means of the set and/or corrected parameter in a second injection molding step and a third injection molding step.
In an embodiment, it may be provided that in the further process, depending on properties of the test element produced in the second injection molding step and/or properties of the test element produced in the third injection molding step, at least one parameter of the first injection molding step and/or at least one parameter of the second injection molding step and/or one parameter of the third injection molding step is set and/or corrected and then the optical element is produced in three injection molding steps with at least one set and/or corrected parameter.
Injection molding parameters within the meaning of this disclosure may be, for example, the following parameters:
Details on injection molding parameters can be found, for example, on pages 65, 66, 67 and 68 of the book “Technologie des Spritzgießens”—Lern-und Arbeitsbuch, Hopmann, Michaeli, Greif, Ehrig, Carl Hanser Verlag München, 2017, ISBN 978-3-448-45042-4. Example interactions between injection molding parameters are shown in FIG. 7.6 on page 67 and FIG. 7.8 on page 69 of the book “Technologie des Spritzgießens”—Lern-und Arbeitsbuch, Hopmann, Michaeli, Greif, Ehrig, Carl Hanser Verlag München, 2017, ISBN 978-3-448-45042-4.
It may also be provided that injection molding parameters within the meaning of the present disclosure are parameters without direct reference to injection molding, such as (peripheral) parameters:
These parameters may be assigned to the first group of injection molding parameters and/or the second group of injection molding parameters. Injection molding parameters within the meaning of this disclosure may, according to one embodiment, be parameters such as geometry parameters (tool contour/geometry). In one embodiment, it may be provided that parameters within the meaning of the present disclosure may also be geometry parameters (lengths, curves, angles, and position of optical axes). It may be provided that parameters in the sense of this disclosure are parameters in the sense of a tool correction or cavity correction, in that these are determined, e.g. depending on correction factors.
Injection molding parameters within the meaning of the present disclosure can be parameters such as dwell time of the pre-injection molded components on the cooling table or injection flow. These parameters can be assigned to the first group of injection molding parameters and/or the second group of injection molding parameters.
A corrected parameter set (PAR) follows, for example, from an initial or previous parameter set, adjusted by correction parameters. To determine the parameters PAR, in one embodiment the correction values are multiplied by their respective target values. Thus, in one embodiment, the parameters PAR result as the product of the respective target value with the respective correction value. For example, if the contour accuracy is to be improved, it may be provided that the target value of a dwell time in the mold is increased by multiplication by a correction factor, or that the holding pressure duration is multiplied accordingly by a correction value>1. Further examples are shown in the following
The determination of correction factors and/or corrected parameters or corrected injection molding parameters takes place e.g.
Correction factors result, for example, from cause-and-effect relationships/knowledge/informations from one or more of the following sources:
Examples of embodiments include:
It may be provided that injection molding parameters within the meaning of the present disclosure may be tool active elements, such as cylinder strokes, cylinder forces (for embossing functions), electrical voltage for piezo actuators, valve movement for controlling air and mass flows. These parameters can be assigned to the first group of injection molding parameters and/or the second group of injection molding parameters.
A surface structure in the sense of the present disclosure is for example a light-scattering surface structure. A light-scattering surface structure in the sense of this disclosure comprises, for example, a modulation and/or a (surface) roughness of at least 0.05 μm, for example at least 0.08 μm, or is designed as a modulation optionally with a (surface-) roughness of at least 0.05 μm, for example at least 0.08 μm. Roughness in the sense of the present disclosure is to be defined for example as Ra, for example according to ISO 4287. In a further embodiment, the light-scattering surface structure may comprise a structure mimicking a golf ball surface or be configured as a structure mimicking a golf ball surface. Suitable light-scattering surface structures are disclosed, for example, in DE 10 2005 009 556 A1, DE 102 26 471 B4 and DE 299 14 114 U1. Further usable embodiments of light-scattering surface structures are disclosed in German patent specification 1 099 964 A, DE 36 02 262 C2, DE 40 31 352 A1, U.S. Pat. No. 6,130,777 and US 2001/0033726 A1.
A light-scattering surface structure or a surface structure within the meaning of this disclosure is not a diffractive or light-diffracting surface structure. For example, it is provided that the replacement of an injection mold with a surface forming a surface structure by a corresponding injection mold forming a smooth surface does not take place if the surface structure is a diffractive or light-diffracting surface structure.
An optically effective surface is, for example, an (optically effective) light exit surface and/or an (optically effective) light entrance surface,
A corresponding smooth mold or injection mold within the meaning of this disclosure is, for example, a corresponding injection mold that molds a surface that forms the contour without the surface structure. A corresponding smooth injection mold within the meaning of this disclosure for example forms a surface with a roughness of not more than 20 nm, for example not more than 10 nm, for example not more than 7 nm, for example not more than 5 nm (for example in connection with a tool, i.e. an injection mold, made of steel). A corresponding smooth injection mold (tool) within the meaning of the present disclosure made of nickel-phosphorus layers for example forms surfaces with a roughness Ra of not more than 2 nm, for example of not more than 1 nm. For example, it may be provided that the roughness of the tool or of the smooth corresponding injection mold comprises a roughness of not less than 0.5 nm. In this context, roughness within the meaning of this disclosure is defined for example as Ra, for example according to DIN ISO 4287.
In one embodiment, it is provided that the optical element comprises at least one further optically effective surface, wherein, in a third injection molding step, a layer of plastic forming the further optically effective surface is injection molded directly or indirectly onto the pre-injection molded component and/or the at least one pre-injection molded component of the preinjection molded part by means of a third injection mold in dependence of a third group of injection molding parameters.
In an alternative embodiment, it is provided that the optical element comprises at least one further optically effective surface with a contour and with a further surface structure superimposed on the contour, wherein in a third injection molding step, by means of a third injection mold, a layer of plastic forming the further optical surface with the further surface structure is injection molded directly or indirectly onto the pre-injection molded component and/or the at least one pre-injection molded component of the pre-injection molded part in dependence of a third group of injection molding parameters. For example, it is provided that the third injection mold is replaced by a smooth injection mold corresponding to the third injection mold, wherein the optical test element is injection molded both by means of the smooth injection mold corresponding to the second injection mold and by means of the smooth injection mold corresponding to the third injection mold.
In a further embodiment, at least one parameter from the first group of injection molding parameters and/or at least one parameter from the second group of injection molding parameters and/or at least one parameter from the third group of injection molding parameters is set and/or corrected as a function of properties of the test element.
In a further embodiment, it is provided that the second injection molding step is performed before the third injection molding step or, alternatively, that the third injection molding step is performed before the second injection molding step.
In another embodiment, the smooth injection mold corresponding to the third injection mold is replaced by the third injection mold, wherein the optical element is injection molded using the third injection mold.
An optical element within the meaning of this disclosure is, for example, a headlight lens. An optical element within the meaning of the present disclosure is, for example, a headlight lens for imaging a bright-dark-boundary on a roadway. An optical element within the meaning of this disclosure is, for example, a converging lens. A finished-molded lens or optical element within the meaning of this disclosure is, for example, a lens or optical element having a volume of at least 50 cm3, for example of 25 cm3, without a sprue.
The term “pre-injection molded component” is used in this disclosure in accordance with WO 2014/161014 A1, whereas the term “injection molded part” is used in deviation from WO 2014/161014 A1 to refer to a lens body (including rim) or multiple lens bodies (including rim) including sprue.
For example, the following terminology is used: A pre-injection molded part comprises at least one sprue and at least one pre-injection molded component. A pre-injection molded part may also comprise a sprue with two or more pre-injection molded components. An injection molded part includes at least one sprue and at least one optical element, or at least one sprue and at least one lens. An optical element or lens comprises a lens body and optionally a lens rim or edge.
The sprue in the sense of this disclosure is formed for example by the plastic (melt) solidified in the supply channels to the casting mold. It is provided that the sprue within the meaning of this disclosure is a part whose volume does not contribute to the volume of the “useful part”, i.e. the volume of the optical element or lens element. Sprue within the meaning of the present disclosure includes what is referred to in English as sprue, runner and gate. A sprue within the meaning of this disclosure or this terminology is for example not limited to sprue in English.
It may be provided that the or a layer forming the optically effective surface is not thicker than 1 mm, for example not thicker than 0.75 mm, for example not thicker than 0.5 mm. A layer forming an optically effective surface or a layer forming an optically effective light entrance surface or a layer forming a light exit surface, for example, is not thicker than X millimeters within the meaning of this disclosure if at least 70%, for example at least 80%, for example at least 90%, of this layer is not thicker than X millimeters.
In a further embodiment, the method is supplemented by one or more of the following features (see WO 2019/179571 A1):
It is for example injection molded at a pressure of not less than 600 bar.
It is for example injection molded at a pressure of not less than 800 bar.
It is for example injection molded at a pressure not exceeding 1000 bar.
The optical element (according to the disclosure) or a corresponding lens is also used, for example, in a projection headlight. In the design as a headlight lens for a projection headlight, the optical element or a corresponding headlight lens reproduces the edge of a shield as the bright-dark-boundary on the road.
An exemplary application relates to a method for manufacturing a vehicle headlight, wherein an optical element produced according to a method having one or more of the aforementioned features is installed in a headlight housing.
Another exemplary application relates to a method for manufacturing a vehicle headlight, wherein an optical element produced according to a method having one or more of the aforementioned features is placed in a headlight housing and assembled together with at least one light source or a plurality of light sources to form a vehicle headlight.
A further exemplary application relates to a method for producing a vehicle headlight, wherein an optical element produced by a method having one or more of the aforementioned features is placed in a headlight housing as a secondary optics or as part of a secondary optics comprising a plurality of lenses for imaging a light output surface of an attachment optics and/or an illumination pattern generated by means of a primary optics and is assembled together with at least one light source or a plurality of light sources and the attachment optics to form a vehicle headlight.
Another exemplary application relates to a method of manufacturing a vehicle headlight, wherein a primary optics or an attachment optics array is produced as the primary optics for generating the illumination pattern in accordance with a method having one or more of the foregoing features.
Another exemplary application relates to a method of manufacturing a vehicle headlight, wherein the primary optics comprises a system of movable micromirrors, for example a system of more than 100,000 movable micromirrors, for example a system of more than 1,000,000 movable micromirrors, for generating the illumination pattern.
Another exemplary application relates to a method for manufacturing an objective, wherein at least a first lens is produced according to a method having one or more of the aforementioned features and is subsequently installed in an objective and/or an objective housing.
In an embodiment, it is provided that the maximum deviation of the actual value from the target value of the distance between two optically effective surfaces of the optical element is not greater than 40 μm, for example not greater than 30 μm, for example not greater than 20 μm, for example not less than 2 μm. In an embodiment, it is provided that the maximum deviation of the actual value from the target value of the distance between an optically effective surface and a plane orthogonal to the optical axis of the optically effective surface, this plane comprising the geometric center of gravity of the optical element, is not greater than 20 μm, for example not greater than 15 μm, for example not greater than 8 μm, for example not less than 1 μm. In an embodiment, it is provided that the value RMSt (total surface shape deviation) according to DIN ISO 10110-5 of April 2016 for the optically effective surfaces of the optical element, for at least one optically effective surface of the optical element and/or for at least two optically effective surfaces of the optical element, is not greater than 12 μm, for example is not greater than 10 μm, for example is not greater than 8 μm, for example is not greater than 6 μm, for example is not greater than 4 μm, for example is not greater than 2 μm, for example is not smaller than 0.5 μm.
Plastic in the sense of this disclosure may be, for example, thermoplastic resin. Thermoplastic plastic in the sense of this disclosure is for example polycarbonate, for example LED 2643, or a thermoplastic resin such as a polycarbonate resin, a polyacrylic resin or a modified polyolefin resin. Examples of thermoplastic resins or thermoplastic resin can be taken for example from DE 699 23 847 T2. For example, DE 699 23 847 T2 discloses as polycarbonate resin the suitable use of aromatic polycarbonate resin obtained by reacting a diphenol and a carbonate precursor. Examples of the diphenol in this context include bis-(hydroxyaryl)alkanes, such as 2,2-bis-(4-hydroxyphenyl)propane (so-called bisphenol A), bis-(4-hydroxyphenyl)methane, 1,1-bis-(4-hydroxyphenyl)ethane, 2,2-bis-(4-hydroxyphenyl)-butane, 2,2-bis-(4-hydroxyphenyl)-octane, 2,2-bis-(4-hydroxyphenyl)-phenylmethane, 2,2-bis-(4-hydroxy-3-methylphenyl)-propane, 1,1-bis-(4-hydroxy-3-tert.-butylphenyl)-propane, 2,2-bis-(4-hydroxy-3-bromophenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dibromophenyl)-propane and 2,2-bis-(4-hydroxy-3,5-dichlorophenyl)-propane; Bis-(hydroxyphenyl)-cycloalkane, such as 1,1-bis-(hydroxyphenyl)-cyclopentane and 1,1-bis-(hydroxyphenyl)-cyclohexane; dihydroxyaryl ethers, such as 4,4′-dihydroxydiphenyl ether and 4,4′-dihydroxy-3,3′-dimethyldiphenyl ether; dihydroxydiaryl sulfides, such as 4,4′-dihydroxydiphenyl sulfide and 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfide; dihydroxydiaryl sulfoxides, such as 4,4′-dihydroxydiphenyl sulfoxide and 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfoxide; and dihydroxydiarylsulfones, such as 4,4′-dihydroxydiphenyl sulfone and 4,4′-dihydroxy-3,3′-dimethyldiphenyl sulfone. These diphenols can be used alone or in a combination of two or more products.
Plastic in the sense of this disclosure may be a thermoplastic or a duroplast. The plastic may be a polycarbonate, a PMMA, a COC (=cyclo olefines copolymer). The plastic may be a CR39. Plastic in the sense of the present disclosure is for example PMMA. In this regard, the respective plastic may have a coefficient of thermal expansion of not less than 6×10−5 mm/K. In an embodiment, the plastic may have a coefficient of thermal expansion of not more than 8×10−5 mm/K. Plastics within the meaning of the present disclosure are, for example, amorphous plastics or polymers. “The atomic structure of polymers mainly involves the non-metal elements carbon (C), hydrogen (H) and oxygen (O). Nitrogen (N), chlorine (CO, fluorine (F) and sulfur (S) also occur relatively frequently (heteroatoms).” See Bauer et al: Saechtling Plastics Pocketbook, 31 ed, (2013). Plastics within the meaning of this disclosure may also be or comprise semi-organic polymers. “So-called semi-organic polymers contain the semimetal elements silicon (Si), referred to as silicones or polysiloxanes, and boron (B).” see Bauer et al: Saechtling Kunststoff Taschenbuch, 31 Aufl, (2013). Plastics within the meaning of the present disclosure may also be or comprise siloxanes. A first plastic according to the present disclosure is different from a second plastic according to the present disclosure. A second plastic as defined in this disclosure may be and/or comprise a semi-organic polymer, a silicone, a polysiloxane, and/or a siloxane.
Motor vehicle in the sense of the disclosure is for example a land vehicle which can be used individually in road traffic. Motor vehicles within the meaning of the disclosure are for example not limited to land vehicles with internal combustion engines.
In addition, individual pre-injection molded parts 2 are phased into the reservoir SP of the manufacturing island FIN according to
The injection molding machine SG1 comprises a mold or cavity (or tool or injection molding tool) P1 by means of which, in an injection molding step 111, the pre-injection molded part 2 shown in
Afterwards the pre-injection molded part 2 with the pre-injection molded components 21 and 22 is fed to the cooling system KUE in a cooling step 112.
The injection molding machine SG2 comprises a mold or cavity (or tool or injection molding tool) P2 for injecting a pre-injection molded part 3 shown in
The injection molding machine SG2 further comprises a mold or cavity (or tool or injection molding tool) P3 for injecting (in an injection molding step 114) a layer 45 of liquid plastic onto the pre-injection molded component 31 as shown in
The manufacturing island FIN also comprises a controller CTRL for controlling the injection molding process, i.e. explicitly for controlling the injection molding machine SG1, the handling robot R, the injection molding machine SG2 and optionally the cooling range KUE. It may be provided that the controller CTRL is not a single control unit, but comprises at least 2 control units which are connected in terms of data by means of a bus system (for example in terms of a master-slave architecture). More details on suitable controllers can be found, for example, in the book “Technokogie des Spritzgießens”—Lern-und Arbeitsbuch, Hopmann, Michaeli, Greif, Ehrig, Cari Hanser Verlag Munich, 2017, ISBN 978-3-448-45042-4 on pages 19, 29, 57, 58, 59, 64, 66, 70, 74 and 76.
The injection molded part 4 according to
By means of the mold or cavity (or tool or injection molding tool) P3, a light-scattering surface structure or modulation is formed in the surface of the optical elements 41 and 42 of the injection molded part 4. For correction of the controller CTRL or its parameters PAR (cf.
For example, it is intended that one or more injection molded optical elements (test elements) by means of the mold P3′ (injection molding step 117) are checked in an optical test bench M with respect to the photometric values or their imaging quality (in a test step 118 according to
The dashed lines in
After the query 115, a tool change of the injection molding tool with the mold or cavity (or tool or injection molding tool) P2, P2′ may also be provided according to
After the query 115, a simultaneous change of the injection molding tool P2, P2′ and the injection molding tool P3, P3′ may also be provided, so that after the query 115, the steps 116, 117, 118 and 119 for the injection molding tool P2, P2′ and the injection molding tool P3, P3′ run in parallel. Thereby, during this simultaneous change of the injection molding tool P2, P2′ and the injection molding tool P3, P3′, the parameters of the injection molding step 111 and/or the parameters of the injection molding step 113 and/or the parameters of the injection molding step 114 can be set and/or corrected.
The liquefied plastic 54 is then pressed into a hot runner system 80 and from there injected into an injection molding tool 60 via hot runner nozzles 81. The injection molding tool 60 as a possible embodiment for the tools P1, P2, P3 or P3′ (as well as tool P2′ (cf.
In the present embodiment, pre-injection molded parts are injection molded (pressed), namely 8 in one injection molding step. Reference sign 71 in
For example, an injection molding machine 500′ shown in
To determine the PAR parameters, the correction values are multiplied by their respective target values. The parameters PAR are thus the product of the respective target value and the respective correction value. For example, if the contour accuracy is to be improved, it may be provided that the target value of a dwell time in the mold is increased by multiplication by a correction value>1, or that the hold pressure duration is multiplied accordingly by multiplication by a correction value>1. Further examples are shown in the following
The correction module KORMA according to
As described above, the correction values are multiplied by their respective target values to determine the parameters PAR. Thus, a corrected target value for the hot runner temperature HKT results from the product of the correction value KHKT, which is determined by the neural network as output variable, for the hot runner temperature HKT and the corresponding target value. A corrected target value for the injection pressure ESD results from the product of the correction value KESD for the injection pressure ESD determined by the neural network as output variable and the corresponding target value for the injection pressure ESD. A corrected target value for the holding pressure NDR is obtained from the product of the correction value KNDR of the holding pressure NDR determined by the neural network as output variable and the corresponding target value of the holding pressure NDR. A corrected target value for the holding pressure duration KNDA results from the product of the correction value KNDA for the holding pressure duration NDA determined by the neural network as output variable and the target value of the holding pressure duration NDA.
The correction module KORMB according to
To determine the parameters, the correction values are multiplied by their respective target values. Thus, a corrected target value for the hot runner temperature HKT results from the product of the correction value KHKT for the hot runner temperature HKT determined by the neural network as output variable and the corresponding target value. A corrected target value for the injection pressure ESD results from the product of the correction value KESD for the injection pressure ESD and the corresponding target value for the injection pressure ESD. A corrected target value for the holding pressure NDR results from the product of the correction value KNDR of the holding pressure NDR determined by the neural network as output variable and the corresponding target value of the holding pressure NDR. A corrected target value for the holding pressure duration KNDA results from the product of the correction value KNDA for the holding pressure duration NDA determined by the neural network as output variable and the target value of the holding pressure duration NDA.
The correction module KORMC according to
To determine the parameters, the correction values are multiplied by their respective target values. Thus, a corrected target value for the injection pressure ESD results from the product of the correction value KESD for the injection pressure ESD determined by the neural network as output variable and the corresponding target value of the injection pressure ESD. A corrected target value for the holding pressure NDR is obtained from the product of the correction value KNDR of the holding pressure NDR determined by the neural network as output variable and the corresponding target value of the holding pressure NDR. A corrected target value for the holding pressure duration KNDA results from the product of the correction value KNDA for the holding pressure duration NDA determined by the neural network as output variable and the target value of the holding pressure duration NDA. A corrected target value for the closing force SKR results from the product of the correction value KSKR for the closing force SKR determined by the neural network as output variable and the corresponding target value of the closing force SKR.
The correction module KORMD according to
To determine the parameters, the correction values are multiplied by their respective target values. Thus, a corrected target value for the holding pressure NDR results from the product of the correction value KNDR of the holding pressure NDR determined by the neural network as output variable and the corresponding target value of the holding pressure NDR. A corrected target value for the closing force SKR results from the product of the correction value KSKR for the closing force SKR and the corresponding target value of the closing force SKR.
The correction module KORME according to
To determine the parameters, the correction values are multiplied by their respective target values. Thus, a corrected target value for the holding pressure NDR results from the product of the correction value KNDR of the holding pressure NDR and the corresponding target value of the holding pressure NDR. A corrected target value for the closing force SKR results from the product of the correction value KSKR for the closing force SKR determined by the neural network as output variable and the corresponding target value of the closing force SKR.
The correction module KORMF according to
To determine the parameters, the correction values are multiplied by their respective target values. Thus, a corrected target value for the holding pressure NDR results from the product of the correction value KNDR of the holding pressure NDR determined by the neural network as output variable and the corresponding target value of the holding pressure NDR. A corrected target value for the closing force SKR results from the product of the correction value KSKR for the closing force SKR and the corresponding target value of the closing force SKR.
In the embodiments according to
It may be provided that the choice of the correction module is made depending on the available database for training a neural network. For example, it may be provided to start with the correction module KORMF according to
Matrix headlights within the meaning of the present disclosure may also be matrix SSL HD headlights. Examples of such headlights are shown in the Internet link www.springerprofessional.de/fahrzeug-lichttechnik/fahrzeugsicherheit/hella-bringt-neues-ssi-hd-matrixlichtsystem-auf-den-markt/17182758 (accessed May 28, 2020), the Internet link www.highlightweb.de/5874/hella-ssl-hd/ (accessed May 28, 2020), and the Internet link www.hella.com/techworid/de/Lounge/Unser-Digital-Light-SSL-HD-Lichtsystem-ein-neuerMeilenstein-der-automobilen-Lichttechnik-55548/ (accessed May 28, 2020).
Another suitable field of application for optical elements or lenses manufactured according to the disclosure is disclosed, for example, in DE 10 2017 105 888 A1 or the headlight described with reference to
The light module M20 has a controller, designated by reference sign M3, which controls the light emitting unit M4 as a function of the values of a sensor system or environmental sensoric M2 of the motor vehicle S100. The concave lens M5 has a concavely curved exit surface on the side facing away from the light emitting unit M4. The exit surface of the concave lens M5 redirects light ML4 irradiated into the concave lens M5 by the light emitting unit M4 with a large irradiation angle toward the rim of the concave lens by means of total reflection, so that it does not pass through the projection optics M6. According to DE 10 2017 105 888 A1, light beams emitted at a ‘large beam angle’ by the light emitting unit M4 are those light beams which (without arrangement of the concave lens M5 in the beam path) would be poorly imaged, for example blurred, on the roadway by means of the projection optics M6 due to optical aberrations and/or which could lead to stray light which reduces the contrast of the image on the roadway (see also DE 10 2017 105 888 A1). It may be provided that the projection optics M6 can only sharply image light with an aperture angle limited to approximately +/−20°. Light beams with aperture angles greater than +/−20°, for example greater than +/−30°, are thus prevented from hitting the projection optics M6 by the arrangement of the concave lens M5 in the beam path.
The light emitting unit M4 can be designed differently. According to one embodiment, the individual point-shaped light sources of the light emitting unit M4 each comprise a semiconductor light source, for example a light emitting diode (LED). The LEDs can be selectively controlled individually or in groups to switch the semiconductor light sources on or off or to dim them. For example, the light module M20 has more than 1,000 individually controllable LEDs. For example, the light module M20 can be designed as a so-called μAFS (micro-structured adaptive front-lighting system) light module.
According to an alternative possibility, the light emitting unit M4 comprises a semiconductor light source and a DLP or micromirror array comprising a plurality of micromirrors that can be individually controlled and tilted, each of the micromirrors forming one of the point light sources of the light emitting unit M4. For example, the micromirror array comprises at least 1 million micromirrors that may be tilted, for example, at a frequency of up to 5,000 Hz.
Another example of a headlight system or light module (DLP system) is disclosed by the Internet link www.al-lighting.com/news/article/digital-light-millions-of-pixels-on-the-road/ (accessed Apr. 13, 2020). A schematically represented corresponding headlight module or vehicle headlight for generating an illumination pattern designated GL7A in
A controller G4 is provided for controlling the system G6 with movable micromirrors. In addition, the headlight G20 includes a controller G3 both for synchronization with the controller G4 and for controlling the lighting device G5 in response to environmental sensoric G2. Details of the controllers G3 and G4 can be obtained from the Internet link www.al-lighting.com/news/article/digital-light-millions-of-pixels-on-the-road/ (accessed Apr. 13, 2020). The illumination device G5 may comprise, for example, an LED arrangement or a comparable light source arrangement, an optical system such as a field lens (which, for example, has also been manufactured according to the described method), and a reflector.
The vehicle headlight G20 described with reference to
The elements or objects in
The disclosure specifies an (improved) production process for optical elements with a surface structure. In this context, a particularly high contour fidelity and/or surface quality for optical elements or lenses or headlight lenses is achieved. In addition, the costs of a production process for optical elements such as headlights or vehicle headlights is reduced.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2020 129 103.5 | Nov 2020 | DE | national |
| 10 2020 134 325.6 | Dec 2020 | DE | national |
| 10 2021 115 907.5 | Jun 2021 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/DE2021/100858 | 10/27/2021 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
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| 20230398722 A1 | Dec 2023 | US |
