Development of Optical-Design Compensation Technique to Extend Manufacture Tolerance for Led-Based Vehicle High-Contrast Headlamp( II )

High-contrast automotive head lamp based on white LED is a high-end technology. The optical design is difficult and the manufacture is tough as well. The problem in manufacture is on plastic forming processing. Owing to machining precision and thermal strain, there are several major failure factors in the molding injection processing so the manufacture tolerance becomes strict. To solve this problem, one is to increase machining precision, and the other is to calculate the thermal deformation before manufacture. Even so, the problem is still there, and the manufacture keeps high.This is a two-year project which is aimed to solve a problem stated above, which is based on the experience we have in collaboration with a company in the past several years. The company has sale headlamp for many years in Europe, Japan and USA. The manufacture in the company suffers from very strict tolerance, which causes delivery delay and cost up. In this project, we want to face a new challenge. All the optical design is targeted to Germany K-mark and Euro E-mark, and both are strict regulations in bike or motorcycle headlamp. In contrast to the general approaches, we propose two different and novel ways to conquer the problem. The first is called post-shaping technique (PoST), where apply a midfield 3D mask (MF3DM) to compensate the distortion through manufacture. The second is called pre-shaping technique (PrST), where we design a component for extension and uniformization (EU) to enlarge manufacturing tolerance for a high-contrast head lamp. Through the project, we can develop very useful optical design to enlarge manufacturing tolerance and effectively reduce the manufacture cost in industry. In addition, we have studied to issue a patent to protect the intelligence and hope to transfer to Taiwan related industry to enhance industrial capability.