白光 LED 高對比度光型車燈是高度技術的產品，不但在光學設計上有難度，在生產製作過程中也會因為塑膠射出成型與機械加工技術上的不足或成本因素而造成各種瑕疵之製作公差問題，導致設計端與生產製造端無法得到一致結果，而造成競爭力不足。此一問題或可利用超精密加工機進行改善，但超精密加工機的高成本與射出時的熱應力仍然是問題。本計畫是一個兩年期的計畫，是建立在研究團隊與本計畫合作企業於多年間的車燈設計與製造經驗基礎上，我們將針對業者長期在車燈生產製造過程中常遭遇到的公差容忍度議題，以嚴謹的德國 K-mark 法規與歐規 E-mark 法規進行驗證。不同於目前國際大廠之車燈光學設計技術，本計畫分別提出「後克服」的中場立體遮罩式 (Midfield 3D mask，MF3DM) 光學補償設計技術以及與「預克服」的均展式 (Extension and uniformization，EU) 光學補償設計技術來進行車燈高對比度光形之設計、燈具製作以及公差容忍度剖析。藉由本計畫所開發之技術能量，研發成果未來不僅可技轉於國內相關車燈生產製造產業，更可嘉惠 LED 各類型照明應用產業，可有效地節省其生產製造成本、縮減其生產製造時程、以及提高企業營收利潤。本技術的基礎專利已經布局，因此本研究對於我國 LED 產業在爭取未來的國際競爭上具有極高優勢。 ;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.
