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`US 20050208210A1
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`(19} United States
`{12) Patent Application Publication (10) Pub. N0.: Us 2005/0208210 A1
`Kuta
`(43) Pub. Date: Sep. 22, 2005
`
`
`{54} HEADLIGHT LENS RESURFACING
`APPARATUS AND METHOD
`
`Publication Classification
`
`Int. CL" .............................. B328 35:00; 1305]) sum
`(51)
`(52) U.S.Cl.
`........................... 427f140;427i162;427L508
`
`(76)
`
`Inventor: Terr}r Mitchell Kuta, Mission Viejo,
`CA (US)
`
`{57)
`
`ABSTRACT
`
`Refinishing an exterior automotive lens having a damaged
`exterior surl'acc in silu using a continuous movement and
`oscillating motion, with first, a 320 grit sanding disc, next a
`600 grit sanding disc and finally a 1500 grit sanding pad
`whilc flushing the surface with water to prevent melting of
`the surface. Bulfing the surface with a polishing compound
`until a high giosg is achieved. Finally, coating the surface
`with a transparenl ultraviolet hardcnahle coating material,
`and hardening il by exposure to an ultraviolet light source.
`This method is accomplished using an oscillating tool hav—
`ing a rcmotcly located drive.
`
`Correspondence Address:
`GENE SCOTT; PATENT LAW 8: VENTURE
`GROUP
`3140 RED HILL AVENUE
`SUITE 150
`COSTA MESA, CA 92626-3440 (US)
`
`Appl. No.:
`
`[0,804,435
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`Filed:
`
`Mar. 18, 2004
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`i }
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`{21
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`(‘3‘)
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`001
`OOl
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`LKQ CORPORATION 1002
`LKQ CORPORATION 1002
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`Patent Application Publication Sep. 22, 2005 Sheet 1 of 3
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`Patent Application Publication Sep. 22, 2005 Sheet 2 of 3
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`US 2005/0208210 A1
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`Patent Application Publication Sep. 22, 2005 Sheet 3 of 3
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`US 2005/0208210 A1
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`Sep. 22, 2005
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`HEADLIGHT LENS RESURFACING APPARATUS
`AND METHOD
`
`BACKGROUND 01" Till; INVENTION
`
`Incorporation by Reference
`
`[0001] Applicant(s) hereby incorporate herein by refer-
`ence, any and all US. patents and US. patent applications
`cited or referred to in this application.
`
`Field of the Invention
`
`[0002] This invention relates generally to resurfacing of
`transparent plastic surfaces due to wear and crazing. and
`more particular to a specific apparatus singly adapted for
`such resurfacing and a method of using the apparatus.
`
`Description of Related Art
`
`[0003] The following an defines the present state of this
`field:
`
`[0004] Coburn, et al., US. Pat. No. 5,027,560 teaches a
`machine for finishing the surface of a lens including a lap
`holder moved orbitally in a first plane, a lens arm support
`having a lens holder, the lens arm support being oscillated in
`a second plane perpendicular to the first plane, the lens arm
`holder being also simultaneously oscillated in a third plane
`perpendicular to the first plane, the lens holder being urged
`toward the lap holder.
`
`[0005] Sherwin, U.S. Pat. No. 4,510,717 teaches an appa-
`ratus for finishing or polishing a surface of a lens with a
`linishing tool. The apparatus includes a main frame, a shaft
`pivotally mounted to the main frame, and eccentric drive
`means driving the shaft in a predetermined orbital motion.
`Lens finishing means are fixedly secured to one end of the
`shaft. A lens carrier is slidably mounted to the main frame
`such as to be reciprocable along a path perpendicular to the
`orbital axis of the shaft. The lens is removably mounted to
`the carrier and is biased by a biasing device against the lens
`finishing tool.
`
`(iulati, et al. U.S. Pat. No. 4,287,018 teaches a
`[0006]
`method and apparatus for edge-grinding stressed laminated
`glass-plastic lens blanks wherein the lens blanks are heated
`during the abrasive edging process to reduce thermal stress
`breakage. The edged lenses are optionally etched to remove
`glass flaws,
`thus providing laminated lenses exhibiting
`improved resistance to thermal stress breakage in use.
`
`[0007] Our prior art search with abstracts described above
`teaches: a machine for finishing the surface of a lens, a lens
`finishing apparatus, and a method for finishing glass-plastic
`laminated lens blanks, but does not
`teach a machine for
`refinishing a damage lens surface Using oscillating motion
`with a power drive remote with respect to an oscillating head
`and does not teach the present method of removal of the
`outer surface of the lens. The present invention fulfills these
`needs and provides further related advantages as described
`in the following summary.
`
`SUMMARY 017 T1113 INVEN'I'ION
`
`[0008] The present invention teaches certain benefits in
`construction and use which give rise to the objectives
`described below.
`
`[0009] Automobile headlamp lenses are generally fabri-
`cated by injection melding of engineering plastics such as
`polycarbonate. The General Electric Company sells poly—
`carbonate resin under the well known name; I..exan®. Such
`lenses are quite clear,
`tough and chemical resistant, but
`suffer from surface crazing due to scratches that cause them
`to become cloudy over time, primarily through normal
`mechanical abrasion in use. The conventional remedy,when
`the lens becomes so cloudy that headlamp light is danger-
`ously reduced,
`is to replace the lens. However,
`this is
`expensive because of the cost of new lenses and also because
`of the high hourly pay rate for mechanics that remove the
`worn lenses and replace them with new ones.
`
`invention teaches an alternative to
`[0010] The present
`replacement that is more cost ell'ective,
`in that it does not
`require removal of worn lenses nor mounting of new ones.
`'I'hus, this approach saves both the cost of new lenses as well
`as the cost of labor for replacement. The present invention
`teaches an apparatus that is ideally suited to removing the
`outer damaged surface of on an existing lens and a method
`for doing so. Therefore,
`the present
`invention method
`removes the abraded surface on a lens while it
`is still
`
`mounted on the vehicle, and restores optical clarity and light
`output to the level of new lenses.
`
`[0011] The present invention teaches the oilinishing of an
`exterior automotive lens having a damaged exterior surface
`in situ using a continuous movement and oscillating motion,
`with first, a 320 grit sanding disc, next a 600 grit sanding
`disc and finally a 1500 grit sanding disc while flushing the
`surface with water to prevent melting of the surface. This is
`followed by buffing the surface with a polishing compound
`until a high gloss is achieved. Finally, the surface is coating
`with a transparent ultraviolet hardenable coating material,
`which is then hardened by exposure to an ultraviolet light
`source. This method is accomplished using an oscillating
`tool having a remotely located drive so as to avoid mixing
`an electric drive with the water used for flushing the opera-
`tion.
`
`[0012] A primary objective of the present invention is to
`provide an apparatus and method of use of such apparatus
`that yields advantages not taught by the prior art.
`
`[0013] Another objective is to provide such an invention
`capable of removing damage surfaces on automobile head-
`light lenses.
`
`[0014] A further objective is to provide such an invention
`capable of being used in a water flooded surface refinishing
`operation without fear of electric shock.
`
`[0015] Other features and advantages of the present inven-
`tion will become apparent from the following more detailed
`description, taken in conjunction with the accompanying
`drawings, which illustrate, by way of example, the prin-
`ciples of the invention.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0016] The accompanying drawings illustrate the present
`invention. In such drawings:
`
`is a perspective view of the invention
`1
`[0017] FIG.
`showing its method of use;
`
`[0018] FIG. 2 is a perspective view ofa sanding apparatus
`thereof;
`
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`US 2005/0208210 A1
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`Sep. 22, 2005
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`[0019] FIG. 3 is a cross sectional view of a portion of the
`sanding apparatus as taken along section line 3-3 in FIG. 2;
`
`[0020] FIG. 4 is a perspective view of a sanding disc of
`the present invention; and
`
`[0021] FIG. 5 is an exploded perspective view of a portion
`of the apparatus shown in FIG. 2.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`[0022] The above described drawing figures illustrate the
`invention in at least one of its preferred embodiments, which
`is further defined in detail
`in the following description.
`"l‘hose having ordinary skill in the art may be able to make
`alterations and modifications in the present invention with-
`out departing from its spirit and scope. Therefore, it must be
`understood that the illustrated embodiments have been set
`forth only for the purposes of example and that they should
`not be taken as limiting the invention as defined in the
`following.
`
`[0023] The present invention is an apparatus and method
`for refinishing the outer su rfacc of automotive lenses 10 in
`situ, that is, without removing them from the automobile, as
`shown in FIG. 1. The lenses 10 have a damaged exterior
`surface 12, primarily crazing of the surface, caused by the
`impact of stones and sand in the roadway, ultra-violet
`damage from the Sun and chemical damage from the envi-
`ronment, including acid rain, roadway chemicals and similar
`mechanical and chemical damage as well as the natural
`aging of hard coatings placed on such lenses at the factory.
`The method is a step—by~stcp process for removing this
`damage,
`to return the lenses 10 to like-new condition
`without the relatively high cost of replacing them. First, a
`line sanding disc 20. of the type shown in FIG. 4, of
`approximately 320 grit, is placed into contact with one of the
`lenses and moved continuously, over the exterior surface 12
`while applying an oscillating motion to the disc 20 and while
`flushing the exterior surface 12 with water 30 to prevent the
`exterior surface 12 from melting due to friction heat buildup
`from the sanding. As the exterior surface 12, primarily
`factory installed hard coating materials, of the lens 10 is
`removed it exposes a non-abraded surface below, which now
`becomes the exterior surface 12. The sanding process is
`stopped when the flushing water 30 turns clear. This same
`motion is repeated using an ultravfine, 600 grit sanding disc
`20 and, again, with the water flush, and stopping the sanding
`when the lens 10 appears clear. Finally, an ultra-ultra fine
`1500 grit sanding pad is moved manually and continuously
`over the exterior surface 12 of the automotive lens 10 until
`limited access corners 14 ot' the lens 10, where the sanding
`disc 20 is unable to reach, become clear and, again, while
`flushing the exterior surface 12 with water 30 as before.
`When the lens 10 is satisfactory and quite clear, it is bufled
`using a buffing compound until a high gloss is achieved.
`Finally, the exterior surface 12 is coated with a transparent
`ultraviolet hardenable coating material, which is then hard-
`ened by exposure to an ultraviolet light source.
`
`the sanding action is achieved by a
`[0024] Preferably.
`rotating shaft 4-0 driven by an AC motor 50. The shaft 40 has
`an eccentric disk 42 at one end which pushes an oscillating
`cage 44 back and forth, and through a linkage 46, causes the
`sanding disk 20, mounted on a disk receiver 47, to rotate
`about 45-60 degrees, first clockwise off center, then back to
`
`center, and then 60 degrees counterclockwise, i.e., a rota-
`tional back and forth oscillation. This type of motion has
`been found to be critical to the present method because,
`coupled with the manual movement of the sanding disc 20
`is has been found to produce the least amount of spot heating
`of the surface. As mentioned above, because polycarbonate
`melts at a relatively low temperature, the sanding discs are
`constantly moved over the surface of the lens and the water
`flush must be continuous. The sanding disc 20 is preferably
`a round, threewinch diameter disc with radial relief slots as
`showri in FIG. 4. It is self adhesive so as to mount onto a
`one-eighth inch thick soft
`foam pad 21, which is itself
`adhesive mounted onto the flexible rubber sanding disk
`receiver 4'? engaged with the linkage 46 from an oscillator
`device 45 as shown in cross-section in FIG. 3.
`
`[0025] Preferably, the first abrasion step uses a line (320
`grit) sanding disc 20 by Cerium Optical Products of Kent,
`England. It is a 3", 7 leaf disc #PTF767. The first abrasion
`step primarily removes a scratch resistant coating applied by
`the lens manufacturer. The second abrasion step uses an
`extra line (600 grit) sanding disc 20, also by Cerium Optical
`Products #PPF767. This step is stopped when clarity is
`restored to the lens which takes about 10 minutes. The third
`
`abrasion step uses an ultra line (1500 grit) manual surfacing
`material to get into corners 14 missed by the prior steps. This
`step takes about 5 minutes, and is used mostly in corners 14
`which are blended into the entire surface 12 of lens 10. The
`lens 10 is next buffed with a Canton flannel buffing wheel
`coated with Premium Buffing Compound produced by Dico
`Products Corporation of Utica, NY. The buffing uses con-
`tinuous circular motion at between 2800 and 3200 rpm for
`approximately 10 to 15 minutes or until a high gloss is
`achieved. Finally, the new surface is polished. The oscillator
`45 is used for the polishing operation. Constant movement
`of oscillator over the lens is used to prevent heat buildup at
`any one point on the lens surface 12. A self adhesive
`polishing pad is applied to receiver 47. A polish, preferably
`Americal Pius #714Y from Transelco Div. of Ferro Corpo-
`ration, Dresden, N.Y. with 1.1 micron particles is used. This
`polish is applied liberally to the lens surface 12 and to a
`polishing pad using an atomizer. It is a high purity aluminum
`oxide polishing compound with low viscosity. A final polish
`is applied using a mapped poromeric pad by Cerium Optical
`Products, configured as a 3", 6 leaf pad #PTYTG. This final
`polishing is continued until all fine scratches are removed.
`
`[0026] After preparing the lens 10, preferably, a scratch
`resistant coating is applied. This is a UV curable coating for
`hard overcoating onto polished lens, and preferably is,
`Tomco Finishing Products, Tomco Armor Coat No-Bake
`Scratch Coat.
`
`[0027] The apparatus, as shown in FIGS. 1-5 comprises a
`motor 50. preferably an 115 volt AC operated motor, or a 12
`volt DC operated motor that may be powered using a 12 volt
`battery. The motor is separated from the oscillator device 45
`by a flexible drive shaft so that water is unlikely to be
`sprayed into the motor 50. It is considered critical to separate
`the motor 50 from the sanding oscillator or oscillator device
`45.
`
`[0028] The flexible cable includes outer sheath 60 and
`threaded cap 61 (FIG. 2). Oscillator device 45 includes
`cable receiver 62, first hearing set 63, hearing block 64 and
`second bearing set 65, all assembled and engaged in the
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`US 2005/0208210 A1
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`Sep. 22, 2005
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`housing shown in FIG. 3. As shown in FIG. 5, linkage 46
`includes bushing 70, third bearing set 71, spring 72, lock-
`ring 73,
`rubber isolator 74 and spindle 75. Spindle 75
`provides a female thread 76 for receiving the threaded stud
`48 of disc receiver 47. Foam pad 2'1 provides compliant
`resilience for sanding disc 20, and this is critical for smooth-
`ing lens 10. It is considered within the capability of one of
`skill in the art to make and use the apparatus ofthis invention
`from the foregoing description and drawing figures.
`
`[0029] As shown in FIG. 1, the water llush l‘or refinishing
`in situ lenses may comprise a bucket 5 with a broad faced
`nozzle 6 and with a spigot 7 for adjustment of water flow.
`Other means for delivering a continuous flow of water to the
`lens surface 12 will be known by those of skill in the art.
`
`[0030] The enablements described in detail above are
`considered novel over the prior art of record and are con-
`sidered critical to the operation of the instant inVention and
`to the achievement of the above described objectives. The
`words used in this specification to describe the invention and
`its various embodiments are to be understood not only in the
`sense of their commonly defined meanings, but to include by
`special definition in this specification: structure, material or
`acts beyond the scope of the commonly defined meanings.
`Thus if an element can be understood in the context of this
`specification as including more than one meaning, then its
`use must be understood as being generic to all possible
`meanings supported by the specification and by the word or
`words describing the element.
`
`[003]] The definitions of the words or elements of this
`described invention and its various embodiments are, there-
`fore, defined in this specification to include not only the
`combination of elements which are literally set forth, but all
`equivalent structure, material or acts for performing sub-
`stantially the same function in substantially the same way to
`obtain substantially the same result.
`In this sense it
`is
`therefore contemplated that an equivalent substitution of two
`or more elements may be made for any one of the elements
`in the invention and its various embodiments or that a single
`element may be substituted for two or more elements in a
`claim.
`
`[0032] Cha nges from the claimed subject matter as viewed
`by a person with ordinary skill in the art, now known or later
`devised, are expressly contemplated as being equivalents
`within the scope of the invention and its various embodi-
`ments. Therefore, obvious substitutions now or later known
`to one with ordinary skill in the art are defined to be within
`the scope of the defined elements. The invention and its
`various embodiments are thus to be understood to include
`what is specifically illustrated and described above, what is
`conceptually equivalent, what can he obviously substituted,
`and also what essentially incorporates the essential idea of
`the invention.
`
`[0033] While the invention has been described with ref-
`erence to at
`least one preferred embodiment,
`it is to be
`
`the
`that
`clearly understood by those skilled in the art
`invention is not limited thereto. Rather, the scope of the
`invention is to be interpreted only in conjunction with the
`appended claims and it is made clear, here, that the inven-
`tor-(s) believe that the claimed subject matter is the inven-
`tion.
`
`What is claimed is:
`
`1. A plastic lens refinishing method comprising the steps
`of: providing an atttomobilc with abraded headlight lenses
`mounted thereon; and for each said headlight lens:
`
`a) sanding with a fine grit sanding disc, over an exterior
`surface of the lens with continuous lateral motions of
`the disc on the exterior surface and with an oscillating
`motion of the disc, while flushing the exterior surface
`with water to prevent the exterior surface from melting,
`for exposing a non-abraded surface of the lens; halting
`the sanding when the flushing water turns clear;
`
`b) sanding with a ultra fine grit sanding disc, over the
`exterior surface of the lens with continuous lateral
`motions of the disc on the exterior surface and with an
`
`oscillating motion of the disc, while flushing the exte-
`rior surface with water to prevent the exterior surface
`from melting; halting the sanding when the lens
`appears clear;
`
`c) sanding with an ultra-ultra fine grit sanding pad, over
`the exterior surface of the lens until
`limited access
`corners of the lens are clear, while flushing the exterior
`surface with water to prevent the surface from melting;
`
`d) polishing the exterior surface with a buffing compound
`until a high gloss is achieved; and
`
`e) coating the exterior surface with a transparent ultra-
`violet hardenable coating material. and hardening the
`coating material by exposure to an ultraviolet
`light
`source.
`
`2. The method of claim 1 wherein the fine grit and the
`ultra-fine grit sanding discs are approximately 3 inches in
`diameter and provide 7 radially oriented and equally spaced
`relief notches therein.
`
`1A refinishing tool apparatus comprising: a drive means
`and a driven means, the drive means and the driven means
`joined by a flexible drive shaft so that the drive means is able
`to control the driven means; the drive means providing an
`electric motor joined with the drive shaft for continuous
`rotation thereof; the driven means providing a receiver for
`interconnection with the drive shaft, the drive shaft termi-
`nating with an eccentric disc, the disc engaged for imparting
`oscillating motion to a sanding disc drive train; a sanding
`disc receiver disc joined to the drive train.
`4. The apparatus of claim 3 further comprising a foam pad
`engaged with the sanding disc receiver disc.
`
`007
`007
`
`