Automotive light optical system with light diffusing projection lens

Abstract

An automotive optical system (100) comprising a first optical element (110) and a second optical element (120), the first optical element reflecting light from a first light source (140a) configured to perform a first illumination function; the second optical element (120) projecting a light beam from the first optical element (110) performing the first illumination function, and wherein a portion of the second optical element (120) is made of a diffusing material. Furthermore, the optical system (100) comprises an auxiliary light source (140b), wherein the second optical element (120) receives light rays from the auxiliary light source (140b) and performs a second illumination function by scattering the light rays received from the auxiliary light source (140b).

Description

Technical Field

[0001] This invention relates to the field of motor vehicle lighting. More specifically, this invention relates to optical systems applied to vehicle lamps. Background Technology

[0002] Original equipment manufacturers (OEMs) and numerous component / system suppliers are striving to improve lighting efficiency and uniformity, particularly for parking lights, turn signals, marker lights, daytime running lights, and signature lights, which are often integrated around headlights and taillights. A particular focus is on the desire to propagate light as uniformly as possible. This invention relates to an innovative solution to provide a lighting and / or signaling device that can perform multiple lighting functions using a single projection lens without employing complex optics on the lens, while simultaneously achieving uniform illumination.

[0003] Typically, automotive lights include one or more optical modules to perform various lighting and / or signaling functions, such as low beam, high beam, and fog light. Each module includes a reflector, a light source that emits light, and a projection lens. The reflector includes a reflective inner surface to reflect at least a portion of the light emitted by the light source toward the projection lens. The projection lens can be made of glass or a polymer material, such as a polymer material selected from polycarbonate or PMMA (polymethyl methacrylate) families.

[0004] Conventional vehicle lights also include folding or shielding elements to create or form a cutoff in the light beam to prevent glare to oncoming vehicles. To achieve a clearer cutoff and perform marker light functions, as well as other auxiliary functions, complex optical elements may need to be added to the projection lens.

[0005] Furthermore, the outer lens or projection lens of conventional automotive lamps can be approximately 25mm thick. Therefore, diffusing or opalescent materials cannot be added to existing projection lenses, as this would reduce the performance of the lighting function. Additionally, since the projection lens is a thick lens, this increases its weight and complicates its manufacturing. The present invention overcomes one or more of these problems of known automotive lamps. Summary of the Invention

[0006] This invention relates to a unique solution to one or more of the problems discussed above. It is believed that the invention provides an optical system used to provide primary illumination functions (low beam, high beam, fogging, etc.) and secondary illumination functions (signature illumination, parking illumination, etc.) by using a single diffuse projection lens and a shaping reflector, and by not using complex optical elements on the projection lens. Furthermore, the optical system can be adapted to add marker light to the (light)beam pattern and further sharpen the gradient at the cutoff of the (light)beam pattern without negatively impacting the performance of the primary illumination functions (i.e., low beam, high beam, and fogging). Therefore, using the optical system of the present invention, simultaneous illumination functions can be performed using a single projection lens.

[0007] Therefore, according to a first aspect of the invention, an optical system for a motor vehicle is envisioned, the optical system comprising: one or more first optical elements that reflect light emitted from a plurality of first light sources, the plurality of first optical elements being configured to perform a first illumination function; a second optical element configured to project a light beam transmitted from the one or more first optical elements configured to perform the first illumination function, wherein at least a portion of the second optical element is made of a diffusing material; and a plurality of auxiliary light sources, wherein the second optical element is configured to receive light emitted from the plurality of auxiliary light sources and to perform a second illumination function by scattering the light received from the plurality of auxiliary light sources.

[0008] The invention is further characterized by one or any combination of the features described herein, such as the plurality of auxiliary light sources being arranged on at least one of the following: multiple sides of the second optical element and the top of the second optical module; the one or more first optical elements being shaping reflectors; the one or more first light sources being arranged near the focal point of the one or more first optical elements; the second optical element being a diffuser lens; the second optical element being arranged downstream of the one or more first optical elements in the associated light propagation direction; the diffuser lens having a thickness of about 2 mm to 7 mm; the plurality of auxiliary light sources being arranged on the top of the flange of the diffuser lens; the plurality of first light sources and the plurality of auxiliary light sources being arranged on the same printed circuit board (PCB); the plurality of first light sources and the plurality of auxiliary light sources being arranged on different printed circuit boards (PCBs); the first (main) lighting function including one of the following: low beam function, high beam function, and fog light function; the auxiliary lighting function being one of the following: signature function, parking function; the diffuser material including at least one of the following polymethyl methacrylate types: Evonik Acrylite (Evonik acrylic or polyacrylate plastic), PMMA 8N LD12, PMMA 8N LD24, and PMMA 8N LD 48, etc. The second optical element is adapted to produce a beam pattern with a sharper cutoff; the top and bottom of the second optical element are made of a non-diffusing material, and the middle portion of the second optical element is made of the diffuser material; the entire portion of the second optical element is made of the diffuser material; the second optical element is manufactured by a multi-shot injection molding process; the second optical element is adapted to increase the sharpness of the cutoff of the beam pattern by utilizing the increased diffuser rate of the diffuser material applied to produce the second optical element; and the second optical element is the outer lens of the optical system.

[0009] Therefore, according to a second aspect of the invention, a headlight assembly for a motor vehicle is envisioned, the headlight assembly comprising: a plurality of low beam modules configured to generate a low beam distribution; a plurality of high beam modules configured to generate a high beam distribution; and wherein at least one of the low beam modules and the plurality of high beam modules includes an optical system comprising: one or more first optical elements configured to reflect light emitted from a plurality of first light sources, the plurality of first optical elements being configured to perform a first illumination function; a second optical element disposed downstream of the one or more first optical elements, the second optical element being configured to project a light beam transmitted from the one or more first optical elements, the one or more first optical elements being configured to perform the first illumination function, wherein at least a portion of the second optical element is made of a diffusing material; and a plurality of auxiliary light sources, wherein the second optical element is configured to receive light emitted from the plurality of auxiliary light sources and perform a second illumination function by scattering the light received from the plurality of auxiliary light sources.

[0010] It should be understood that the aspects and examples mentioned above are non-limiting, as are other aspects present in this invention, as shown and described herein. Attached Figure Description

[0011] The invention and its many accompanying advantages will be better understood by referring to the detailed description herein in conjunction with the accompanying drawings, thus readily providing a more complete understanding of the invention and its many accompanying advantages, in which:

[0012] Figure 1 An optical system for a vehicle lamp assembly according to an embodiment of the present invention is shown.

[0013] Figure 2 This is a schematic arrangement of different components of an optical system according to an embodiment of the present invention, wherein the reflector is a shaping reflector and the lens is a diffuse projection lens.

[0014] Figure 3a illustrates the arrangement of the shaping reflector, the diffuse projection lens, and the auxiliary light source in an optical system according to an embodiment of the present invention.

[0015] Figure 3b illustrates the arrangement of the shaping reflector, the diffuse projection lens, and the auxiliary light source in an optical system according to another embodiment of the present invention.

[0016] Figure 3c shows the path of light, particularly the light emitted from the auxiliary light source when the second light source is arranged as shown in Figure 3b.

[0017] Figures 4a, 4b, 4c and 4d show exemplary luminous intensity distribution results of the low beam module (flat) of the vehicle lamp assembly according to an exemplary embodiment of the present invention, wherein the same projection lens is applied with different levels of diffuser material (from the minimum amount to the maximum amount of diffuser material).

[0018] Figure 5a illustrates an exemplary luminous intensity distribution of a flat low beam module of a vehicle lamp assembly according to an exemplary embodiment of the present invention, the vehicle lamp assembly having a conventional projection lens without diffuser material.

[0019] Figure 5b shows the emission distribution of Figure 5a projected onto a test surface (wall) according to an exemplary embodiment of the present invention, and a curve indicating the gradient change along the (light) beam pattern.

[0020] Figure 6a illustrates an exemplary luminous intensity distribution of a flat low beam module of a vehicle lamp assembly according to an exemplary embodiment of the present invention, the vehicle lamp assembly having a diffuse projection lens.

[0021] Figure 6b shows the emission distribution of Figure 6a projected onto a test surface (wall) according to an exemplary embodiment of the present invention, and a curve indicating the gradient change along the (light) beam pattern.

[0022] Figure 7a shows an exemplary luminous intensity distribution of the full low beam module (flat and bent) of a vehicle lamp assembly with a diffuse projection lens according to an exemplary embodiment of the present invention.

[0023] Figure 7b shows the light emission distribution of Figure 7a projected onto a test surface (wall) according to an exemplary embodiment of the present invention.

[0024] Figure 8 An optical system according to another embodiment of the invention is shown, wherein the diffuse projection lens is manufactured by a multi-shot injection molding process.

[0025] Figure 9a illustrates the intended illumination aspect of an illumination module having a conventional projection lens without diffuser material according to an exemplary embodiment of the present invention.

[0026] Figure 9b illustrates an enhanced illumination aspect of an illumination module with a multi-ray diffuse projection lens according to an exemplary embodiment of the present invention.

[0027] Figure 10a shows an exemplary luminous intensity distribution of a flat low beam module of a vehicle lamp according to an exemplary embodiment of the present invention, the vehicle lamp having a multi-projection lens without diffuser material.

[0028] Figure 10b shows an exemplary luminous intensity distribution of a flat low beam module of a vehicle lamp according to an exemplary embodiment of the present invention, the vehicle lamp having a multi-ray diffuser projection lens. Detailed Implementation

[0029] This invention relates to an optical system for motor vehicles, particularly an optical system for vehicle lights. The optical system can be configured to provide primary illumination functions (low beam, high beam, fogging, etc.) and secondary illumination functions (signature illumination, parking, etc.) by using a single diffuse projection lens and a shaping reflector, and by avoiding the use of complex optical elements on the projection lens. Furthermore, the optical system can be adapted to add marker light to the (light)beam pattern and further sharpen the gradient at the cutoff portion of the (light)beam pattern without negatively impacting the performance of the primary illumination functions (i.e., low beam, high beam, and fogging). Therefore, using the optical system of this invention, simultaneous illumination functions can be performed using a single projection lens.

[0030] Figure 1 An optical system for a vehicle lamp assembly according to an embodiment of the present invention is shown. The optical system 100 includes one or more first optical elements 110, which reflect light from a plurality of first light sources 140a (not in...). Figure 1 It is shown in the middle but Figure 2 (As shown in the diagram) The emitted light is configured to perform a first illumination function. The optical system 100 discussed herein may be part of a low beam module, a high beam module, a matrix light module, or a fog light module. For example, the first or main illumination function includes one of the following: a low beam function, a high beam function, and a fog light function. For example, the low beam module of the vehicle lamp assembly performs the low beam function, and the high beam module of the vehicle lamp assembly performs the high beam function.

[0031] In one embodiment, one or more first optical elements 110 are shaping reflectors or shaping collectors, which will refer to Figure 2 Detailed explanation. The optical system 100 also includes a second optical element 120 configured to project a light beam transmitted from one or more first optical elements 110. In one aspect, the second optical element 120 is a projection lens or outer lens of a vehicle headlight assembly. In one embodiment, at least a portion of the second optical element 120 is made of a diffuser material. In another embodiment, the entire second optical element 120 is made of a diffuser material. The second optical element can be referred to as a diffuse projection lens because it is made of a diffuser material. Furthermore, Figure 1 The optical system 100 shown includes a housing 130 to enclose different components of the vehicle lamp assembly.

[0032] In addition, the optical system 100 includes a plurality of auxiliary light sources 140b (as shown in Figures 3a and 3b). A second optical element or diffuse projection lens 120 can be configured to receive light emitted from the plurality of auxiliary light sources and perform an auxiliary illumination function by scattering the light received from the plurality of auxiliary light sources 140b. For example, the auxiliary illumination function is one of the following: a signature function, a parking function. Specifically, the diffuse projection lens 120 of the optical system 100 can be adapted to provide the auxiliary illumination function and also increase or improve the marking light and further smooth the gradient without degrading the performance of the main illumination function. Furthermore, the diffuse projection lens 120 helps to improve the uniformity of the (light) beam pattern.

[0033] It can be expected that the relationships between components and component assemblies are crucial in solving one or more problems described in the background section above. Each of the components and component assemblies, as well as their associated relationships, are disclosed in more detail and specificity in the following paragraphs.

[0034] Shaping reflector 110

[0035] The primary functional objective of a reflector is to capture the maximum possible share of luminous flux radiated by a light source and direct it toward the road. Various reflector systems are available to allow headlight designers to meet this requirement as effectively as possible.

[0036] The shaping reflector 110 is as follows Figure 2 One reflector shown includes a cutoff profile 135 at the bottom of the reflector, which is part of the reflector itself. Specifically, the cutoff is generated by the rear edge of the reflective surface of a shaping collector. Therefore, no shielding or folding element is needed to generate the cutoff in the beam pattern. Typically, the shaping collector may include an elliptical or parabolic reflective surface.

[0037] exist Figure 2 The shaped reflector 110 shown is an elliptical reflector with a cutoff profile 135. The cutoff profile 135 of the shaped reflector 110 helps to create a cutoff in the beam. Figure 2 The elliptical reflector shown is for illustrative purposes. However, the reflector can be any known type of reflector without any limitations. The reflection collector 110 also includes a first focal point 118 near the rear edge of the reflective surface. The reflective surface of the shaping reflector 110 is configured to collect light emitted by the first light source 140a and reflect it toward the projection lens 120, as shown. Figure 2 As shown in the figure. In addition, the optical system 100 with the shaping reflector 110 is configured to form a light-emitting image on the reflective surface.

[0038] Projection lens 120

[0039] The projection lens 120 is used to project a light beam onto the road. In this invention, the second optical element is the projection lens 120, which projects the light reflected by the shaping reflector 110. Furthermore, the projection lens 120 is also referred to as the outer lens, and the thickness of a conventional vehicle headlight's projection lens can be approximately 25 mm. Therefore, diffusing or opalescent materials cannot be added to existing projection lenses, as this would reduce the performance of the lighting function.

[0040] The lens 120 of the present invention is considered thin, for example, having a thickness of less than 7 mm along the optical axis of the device, particularly because of its small lens height and long focal length. Since the lens has a thickness of approximately 2 mm to 7 mm, it allows the use of diffusing materials. Figure 1 As shown, lens 120 has a second focal point 124.

[0041] Diffuse materials

[0042] Diffusing materials can represent different grades of light scatterers. Diffusing or opalescent materials include materials that promote or help scatter light emitted from a light source. Without limitation, examples of diffuser or opalescent materials include various grades of silicone, polycarbonate or polymethyl methacrylate (PMMA), highly transmissive plastics (such as PS (polystyrene), etc.), COC (cyclic olefin copolymer), PET (polyethylene terephthalate), glass, resin, Evonik Endlighten or similar application materials, and various grades of other opalescent materials. Furthermore, different grades of diffuser materials can be used to form projection lenses. For other examples, different grades of diffuser materials include at least one of the following polymethyl methacrylate types: Evonik Acrylite, PMMA 8N LD12, PMMA 8N LD24, and PMMA 8N LD 48, etc. Projection lenses made of diffuser materials are called diffuse projection lenses. As the diffusion rate of the diffusing material increases, the diffusing projection lens helps to increase the sharpness of the cutoff portion of the beam pattern.

[0043] Light source (140a, 140b)

[0044] A light source represents a source of electromagnetic radiation or radiant energy perceived visually (including "visible" light within the electromagnetic spectrum), but can include a wide combination or range of electromagnetic or radiant energy, including X-rays, ultraviolet and infrared energy, microwaves, and radio waves. A light source can include any conventional and suitable basic lighting source, such as filament-based lamps or incandescent lamps, fluorescent lamps, arc or gas discharge lamps, light-emitting diodes (LEDs), or other suitable conventional sources.

[0045] gradient

[0046] The gradient is a function of intensity and is defined as the logarithm of the intensity at point A in the intensity region of the beam pattern minus the logarithm of the intensity at the adjacent point B in the intensity region of the beam pattern. The gradient is highest at the cutoff point of the (light) beam pattern. Typically, the gradient is in the range of 0.2 to 0.25.

[0047] Bending or elbow

[0048] A beam pattern having a cutoff profile referred to as a "bend" or "knob". As known to those skilled in the art, a cutoff is a defined cutoff line below which light from the headlight assembly is projected. Typically, the light output is below the cutoff below the eyes of a driver in an oncoming vehicle.

[0049] Low beam function

[0050] The low beam module of the headlight assembly performs the low beam function to produce low beams. Low beams provide sufficient light distribution for both forward and side illumination without glare to oncoming vehicles. Low beams can also be referred to as passing beams or dipped beams.

[0051] High beam function

[0052] The high beam module of the headlight assembly performs the high beam function to produce high beam. High beam is a centrally weighted light distribution without glare control. High beam can also be called main beam or full beam.

[0053] Fog light function

[0054] The fog light module of the headlight assembly performs the fog light function to produce fog light, which is a wide strip (light) beam with a clearer cutoff.

[0055] Parking light function

[0056] The parking light function is activated to indicate to other drivers the driver's intention to park the vehicle in an empty parking space. The parking light function is typically performed by parking lights, which are usually located at the rear of the vehicle.

[0057] Signature lighting function

[0058] Signature lights are motor vehicle lights with a specific shape, design, and appearance to help distinguish or identify vehicles. Signature lights are suitable for performing signature illumination functions.

[0059] Marker light

[0060] The propagation of light above the cutoff point of a beam pattern is called sign light. Sign light is used to illuminate road signs, stop signs, etc. In conventional optical systems, specialized optics may be required to obtain sign light. According to the present invention, a diffusing material helps to add sign light to the beam pattern.

[0061] Diffuse rate

[0062] The diffuser ratio of a material is defined as the ratio of its light-guiding conductivity to its density. The number of scatterers in a diffuser increases with increasing diffuser ratio.

[0063] Figure 2 This is a schematic arrangement of different components of an optical system 100 according to an embodiment of the present invention, wherein the reflector is a shaping reflector 110 and the lens is a diffuse projection lens 120. As discussed above, the combination of the shaping reflector 110 and the diffuse projection lens 120 helps to improve the uniformity of the (light) beam pattern of the main illumination functions (such as low beam, high beam, and fog beam). Furthermore, the diffuse projection lens helps to perform auxiliary illumination functions without negatively impacting the main illumination functions. Figure 2 As can be seen, the light beam emitted from the first light source 140a is reflected by the reflective surface of the shaping reflector 110, and from there, the reflected light is guided toward the diffuse projection lens 120 to perform the main illumination function. The first light source 140a and the auxiliary light source 140b include multiple light-emitting diodes (LEDs). In an embodiment, the first light source 140a is arranged near the focal point of the shaping reflector 110, such as... Figure 2 As shown in [the image]. For the sake of brevity, in [the image]... Figure 2 A shaping reflector 110 is shown in the figure. However, the first optical element 110 may include a plurality of shaping reflectors arranged in a laterally series, as shown in Figures 3a and 3b. Light emitted from the first light source 140a is reflected by the shaping reflector 110 and propagated through the thin cross section of the diffuse projection lens 120 to perform the first illumination function.

[0064] In one embodiment of the invention, the auxiliary light source 140b can be disposed on the side of the diffuse projection lens 120, as shown in FIG3a. In this arrangement, light emitted from the auxiliary light source 140b is propagated through a longer path, thereby increasing light scattering. For example, the diffuse projection lens 120 can be modified at the side to arrange the auxiliary light source 140b at the side so that light transmission through the diffuse projection lens 120 is then scattered by the diffuse material for use as a signature or parking function.

[0065] In another embodiment of the invention, as shown in FIG3b, the auxiliary light source 140b may be located on top of the diffuse projection lens 120. For example, the auxiliary light source 140b may be located on top of the flange of the diffuse projection lens. With this arrangement, light emitted from the auxiliary light source 140b is guided toward the diffuse projection lens 120 through one or more light guides 150 (shown in FIG3c), and then the light is scattered by the diffuser material for use as a signature or parking function.

[0066] However, in another embodiment, some auxiliary light sources 140d may be located on the side of the diffuse projection lens 120, and the remaining auxiliary light sources 140d may be located on the top of the module.

[0067] Figures 4a to 4d illustrate exemplary luminous intensity distributions of a low beam module (flat) of a vehicle lamp according to an exemplary embodiment of the present invention, wherein the projection lens is made of different grades of diffuser material. Although a low beam module with a diffuser projection lens is used to perform photometric simulation, those skilled in the art will understand that a high beam module or a fog light module with a diffuser projection lens can be used to perform photometric simulation. The projection lens is made of different grades of diffuser material with different diffuser rates to perform photometric simulation. For example, different grades of diffuser material include PMMA 8N LD12, PMMA 8N LD24, PMMA 8n LD48, and PMMA 8N LD96. For simplicity, diffuser material with the grades mentioned above is used to produce the projection lens. However, those skilled in the art will understand that any type of diffuser material can be used to obtain a diffuser projection lens.

[0068] For example, the diffuser PMMA 8N LD96 has a smaller diffuser than PMMA 8N LD 48, and PMMA 8N LD 48 has a smaller diffuser than PMMA 8N LD24. Furthermore, PMMA 8N LD24 has a smaller diffuser than PMMA 8N LD12.

[0069] In Figures 4a to 4d, the horizontal axis H and the vertical axis V represent the horizontal and vertical planes that intersect the center of the screen and the headlight.

[0070] Figure 4a shows the luminous intensity distribution of the low beam module when the projection lens is made of PMMA 8N LD96 (minimum diffuser material). In Figure 4a, reference numeral 160a indicates the luminous intensity distribution. The maximum intensity is located at -8.6 degrees along the horizontal axis and -2 degrees along the vertical axis. The maximum intensity shown is 15900 cd, and the total luminous flux is 853.

[0071] Figure 4b shows the luminous intensity distribution when the projection lens is made of PMMA 8N LD48. In Figure 4b, reference numeral 160b indicates the luminous intensity distribution. The maximum intensity is located at -7.3 degrees along the horizontal axis and -2 degrees along the vertical axis. The maximum intensity shown is 15700 cd, and the total luminous flux is 834.

[0072] Figure 4c shows the luminous intensity distribution when the projection lens is made of PMMA 8N LD24. In Figure 4c, reference numeral 160c indicates the luminous intensity distribution. The maximum intensity is located at -8.2 degrees along the horizontal axis and -2 degrees along the vertical axis. The maximum intensity shown is 14900 cd, and the total luminous flux is 806.

[0073] Furthermore, Figure 4d shows the luminous intensity distribution when the projection lens is made of PMMA 8N LD12. In Figure 4d, reference numeral 160d indicates the luminous intensity distribution. The maximum intensity is located at -7.3 degrees along the horizontal axis and -2 degrees along the vertical axis. The maximum intensity shown is 13800 cd, and the total luminous flux is 750.

[0074] As can be seen from Figures 4a to 4d, the luminous intensity distributions or beam patterns 160a, 160b, 160c, and 160d include an upper flat cutoff portion 162 that is substantially flush with the horizontal axis H. This cutoff portion is not perfectly straight; it has curvature corresponding to the aberrations in the resulting image. As can be seen from Figures 4a to 4d, the cutoff portion becomes sharper as the diffuser rate increases.

[0075] Furthermore, as can be seen from Figures 4a to 4d, light scattering increases with the increase of the diffuser rate of the diffuser material. For example, the light scattering in Figure 4b is greater than that in Figure 4a. Additionally, the light scattering in Figure 4c is greater than that in Figure 4b, and the light scattering in Figure 4d is greater than that in Figure 4c. Moreover, it can be observed from Figures 4a to 4b that the total output flux of the near-beam module (flat) decreases with the increase of the diffuser rate of the projection lens. Therefore, the selection of the diffuser material grade is important, allowing for increased light scattering to perform the secondary illumination function without degrading the beam pattern, while adding a marker light and mitigating the gradient at the beam pattern cutoff. Furthermore, photometric simulation results show that using a diffuser material is feasible for the projection lens.

[0076] In another exemplary embodiment of the invention, photometric simulations are performed to understand the performance of a flat low beam module having a conventional projection lens and a diffuse projection lens.

[0077] Figure 5a shows test results of an exemplary luminous intensity distribution of a flat low beam module of an indicator lamp according to an embodiment of the present invention, wherein the lamp has no diffusion from a projection lens. In Figure 5a, reference numeral 165a denotes the luminous intensity distribution. The maximum intensity is located at a position of -8.3 degrees along the horizontal axis and -2.1 degrees along the vertical axis. The maximum intensity illustrated is 15900 cd, and the total luminous flux is 857. Figure 5b shows the luminous intensity distribution of Figure 5a projected onto a test surface (wall) and curve 165b indicating the gradient change along the (light) beam pattern.

[0078] Figure 6a shows test results of an exemplary luminous intensity distribution of a flat low beam module of an indicator lamp with a diffuser lens according to an embodiment of the present invention. In Figure 6a, reference numeral 170a denotes the luminous intensity distribution. The maximum intensity is located at a position of -8.6 degrees along the horizontal axis and -2 degrees along the vertical axis. The maximum intensity illustrated is 14500 cd, and the total luminous flux is 797. Figure 6b shows the luminous intensity distribution of Figure 6a projected onto a test surface (wall) and curve 170b indicating the gradient change along the (light) beam pattern.

[0079] As can be understood from Figures 5a and 6a, the cutoff portion of the beam pattern is sharpened by adding a diffuser. Furthermore, as can be seen from the curves in Figures 5b and 6b, the gradient has decreased from 0.24 to 0.22 when the projection lens is made of a diffuser. Due to the presence of scatterers in the diffuser, the gradient at the cutoff portion of the beam pattern decreases from 0.24 to 0.22. Therefore, by using a diffuser projection lens, the gradient of the (light)beam is smoothed without affecting the near-beam function. Moreover, as can be observed from the curves in Figures 5b and 6b, the gradient is highest at the cutoff portion and gradually decreases throughout the (light)beam pattern, i.e., gradually decreasing in the vertically downward direction. Therefore, the diffuser projection lens helps to mitigate the gradient and has minimal impact on hot spot performance. This allows the diffuser projection lens to be used as an auxiliary function. Therefore, the photometric simulation results shown in Figures 5a and 6a demonstrate that the diffuser improves near-beam performance while allowing for auxiliary functions.

[0080] In another exemplary embodiment of the invention, photometric simulation tests are performed to understand the performance of a full low beam module (bent and flat) with a diffused projection lens. For example, the full low beam module may include a flat low beam module and a bent low beam module. Figure 7a shows test results of an exemplary luminous intensity distribution of a full low beam module of an indicator lamp with a diffused projection lens according to an embodiment of the invention. In Figure 7a, reference numeral 175a denotes the luminous intensity distribution. The maximum intensity is located at 0.6 degrees along the horizontal axis and -1.1 degrees along the vertical axis. The maximum intensity illustrated is 49600 cd, and the total lumen flux is 970. Figure 7b shows the luminous intensity distribution of Figure 7a projected onto a test surface (wall) according to an embodiment of the invention. As can be seen from Figure 7a, the total flux of the full low beam module with the diffused projection lens is approximately 970 lumens. Furthermore, as can be seen from Figure 7a, the diffused projection lens 120 helps to increase or improve the indicator light 175b.

[0081] Figure 8 An optical system 200 according to another embodiment of the present invention is shown, wherein a projection lens 205 is manufactured by a multi-shot injection molding process. According to this embodiment, the projection lens 205 can be formed from various opalescent or diffusing materials with different regions 210, 220, and 230 having different diffraction levels. A multi-shot injection molding process can be used to form projection lenses 205 with different regions 210, 220, and 230. Multi-shot injection molding processes are well known to those skilled in the art and are therefore not discussed in detail. For the sake of brevity, Figure 8 The projection lens 205 shown is formed with three different regions 210, 220 and 230, which have different levels of diffraction due to the application of different grades of opalescent or diffusing materials.

[0082] Figures 9a and 9b illustrate a feature according to an embodiment of the present invention. Figure 8 Regarding the illumination aspect of the illumination module of the multi-projection lens, the multi-projection lens is made of and is not made of a diffusing material. Reference numeral 240 indicates illumination with a light pattern when the multi-projection lens is made of exemplary lens materials of various opalescent colors or diffusing grades, or when no diffusing material is used. Furthermore, reference numeral 245 in FIG. 9b indicates illumination with a light pattern when the multi-projection lens is made of the exemplary, mentioned diffusing material. It can be clearly seen from FIG. 9b that the addition of diffusing material improves the overall illumination aspect and also makes it more uniform.

[0083] Furthermore, the addition of a diffuser material helps the dead zone of the lens absorb light. In Figure 9b, the illuminated portion is made of a diffuser material, while the portion outside the illuminated portion is made of a non-diffuse material.

[0084] Figures 10a and 10b show test results of exemplary luminous intensity distributions of flat low beam modules with multi-projection lenses for vehicle lamps according to an exemplary embodiment of the present invention, the lamps having and without diffusion, respectively. Figure 10a shows the luminous intensity distribution of a flat low beam module with a multi-projection lens made of a common lens material without diffusion. In Figure 10a, reference numeral 250 indicates the luminous intensity distribution. The maximum intensity is located at -8.3 degrees along the horizontal axis and -2.1 degrees along the vertical axis. The illustrated maximum intensity is 15900 cd, with a total luminous flux of 857. Figure 10b shows the luminous intensity distribution of a flat low beam module with a multi-projection lens that has diffusion. In Figure 10b, reference numeral 255 indicates the luminous intensity distribution. The maximum intensity is located at -9.8 degrees along the horizontal axis and -1.9 degrees along the vertical axis. The illustrated maximum intensity is 14300 cd, with a total luminous flux of 804. For example, a multi-projection lens uses the diffuser PMMA 8N LD12 to diffuse the light. The gradient obtained with the diffused multi-projection lens is approximately 0.25, while the gradient obtained with the undiffused multi-projection lens is approximately 0.28. Therefore, by using the diffuser, the gradient has been improved without degrading the near beam performance. For example, the calculated luminous efficacy is 0.48 with the undiffused multi-projection lens, while it is approximately 0.45 with the diffused multi-projection lens. Therefore, the addition of the diffuser helps to sharpen the gradient at the cutoff point of the (light) beam pattern without degrading the near beam performance.

[0085] Therefore, adding a diffuser to the projection lens helps to add marker light to the (light)beam pattern without using complex optical elements. Furthermore, it helps to sharpen the gradient at the cutoff point of the (light)beam pattern. Additionally, the diffuser helps to provide uniform illumination by scattering light guided within the material.

[0086] Although this disclosure is provided with reference to the accompanying drawings, all embodiments shown in the drawings are intended to explain preferred embodiments of the invention by way of example and are not intended to limit the invention.

[0087] Those skilled in the art will understand that various changes or modifications can be made to this disclosure without departing from the principles and spirit of this disclosure as covered by the present invention, provided that such changes or modifications fall within the scope of the claims and their equivalents.

[0088] Any numerical value described herein includes all values ​​ranging from lower to higher values ​​in increments of one unit, provided that there is an interval of at least two (2) units between any lower and any higher value. As an example, if the value of a component quantity or process variable (such as, for example, temperature, pressure, time, etc.) is stated as ranging from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it means that values ​​such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc., are explicitly listed in this specification. For values ​​less than 1, one unit is considered as 0.0001, 0.001, 0.01, or 0.1, as appropriate. These are merely examples of specific contemplation, and all possible combinations of numerical values ​​between the listed lowest and highest values ​​will be considered to be explicitly stated in this application in a similar manner.

[0089] Unless otherwise stated, all ranges include both the endpoints and all numbers between them. When combining ranges, use "about" or "approximately" to apply to both ends of the range. Therefore, "about 20 to 30" is intended to cover "about 20 to about 30", including at least the specified endpoints.

[0090] All publicly available content in articles and references, including patent applications and publications, is incorporated by reference for all purposes.

[0091] The term “consistent essentially of” used to describe a combination will include the identified element, component, part, or step, and will also include other elements, components, parts, or steps that do not substantially affect the essential and novel characteristics of the combination.

[0092] List of reference numerals

[0093] Optical System 100

[0094] First optical element or shaping reflector 110

[0095] Second optical element or diffuse projection lens 120

[0096] 130 housing

[0097] The cutoff profile of the shaped reflector 135

[0098] 136 Diffuse or opalescent materials

[0099] First light source 140a

[0100] Auxiliary light source 140b

[0101] First Focus 118

[0102] Second Focus 124

[0103] 145a of light from the first light source

[0104] Light 145b from the second light source

[0105] 150mm optical fiber

[0106] Luminous intensity distribution (projection lens made of PMMA8N LD96) 160a

[0107] Luminous intensity distribution (projection lens made of PMMA8N LD48) 160b

[0108] Luminous intensity distribution (projection lens made of PMMA8N LD24) 160c

[0109] Luminous intensity distribution (projection lens made of PMMA8N LD12) 160d

[0110] (Light) beam pattern cutoff section 162

[0111] Luminous intensity distribution of a flat near beam module (projection lens without diffuser material) 165a

[0112] Gradient curve 165b

[0113] Luminous intensity distribution of a flat near beam module (projection lens with diffuser material) 170a

[0114] Gradient curve 170b

[0115] The luminous intensity distribution of the full low-light module (projection lens with diffuse material) is 175a.

[0116] Marker light 175b

[0117] Optical system with multi-projection lens 200

[0118] Multi-projection diffuser lens 205

[0119] Different regions 210, 220, and 230 of the multi-projection diffuse lens.

[0120] Diffuse illumination without a projection lens 240

[0121] Illumination aspect with diffuse projection lens 245

[0122] Luminous intensity distribution of a flat near beam module with a multi-projection lens without diffuser material 250 Luminous intensity distribution of a flat near beam module with a multi-projection lens without diffuser material 255.

Claims

1. An optical system for a motor vehicle, the optical system comprising: A plurality of first optical elements (110) are configured to reflect light emitted from a plurality of first light sources (140a) and to perform a first illumination function, wherein the first optical elements are shaping reflectors (110). A second optical element (120) is configured to project light reflected from the plurality of first optical elements (110), wherein at least a portion of the second optical element (120) is made of a light-diffusing material; and A plurality of auxiliary light sources (140b), wherein the second optical element (120) is configured to receive light emitted from the plurality of auxiliary light sources (140b) and is configured to perform a second illumination function by scattering the light received from the plurality of auxiliary light sources (140b). The second optical element is a light-diffusing projection lens. Part of the second optical element is formed by multi-shot injection molding, wherein different regions (210, 220, 230) have different levels of diffraction due to the application of different grades of opalescent or diffusing materials.

2. The optical system according to claim 1, wherein, The plurality of auxiliary light sources are arranged on at least one of the following: a plurality of sides of the second optical element, the top of the flange of the light-diffusing lens, and the top of the second optical element.

3. The optical system according to claim 1, wherein, The first light source is positioned near the focal point of the first optical element.

4. The optical system according to claim 1, wherein, The second optical element is arranged downstream of the first optical element along the direction of propagation of the associated light rays.

5. The optical system according to claim 1, wherein, The light-diffusing projection lens has a thickness of 2 mm to 7 mm.

6. The optical system according to claim 1, wherein, The second optical element is adapted to produce a beam pattern with a clearer cutoff.

7. The optical system according to claim 1, wherein, The first light source and the auxiliary light source are arranged on the same printed circuit board (PCB) or on different PCBs.

8. The optical system according to claim 1, wherein, The first lighting function is at least one of the following: low beam function, high beam function, signature function, parking function, and fog light function.

9. The optical system according to claim 1, wherein, The entire portion of the second optical element is made of the diffuse material.

10. The optical system according to claim 1, wherein, The diffuse material includes a collection of PMMA materials with different diffuse properties.

11. The optical system according to claim 6, wherein, The second optical element is adapted to reduce the sharpness of the cutoff portion of the beam pattern by utilizing the increased light diffraction rate of the diffusing material applied to produce the second optical element.

12. A headlight assembly for a motor vehicle, comprising: Multiple low beam modules, the multiple low beam modules being configured to generate a low beam distribution; Multiple high beam modules, the multiple high beam modules being configured to generate high beam distribution; Wherein, at least one of the plurality of low beam modules and the plurality of high beam modules includes an optical system, the optical system comprising: A plurality of first optical elements, the plurality of first optical elements being configured to reflect light from a plurality of first light sources, the plurality of first optical elements being configured to perform a first illumination function, wherein the first optical elements are shaping reflectors; A second optical element, disposed downstream of the first optical element, is configured to project a light beam reflected from the first optical element, wherein a portion of the second optical element is made of a light-diffusing material; and Multiple auxiliary light sources, wherein the second optical element is configured to receive light from the auxiliary light sources and to perform a second illumination function by scattering the light from the auxiliary light sources. The second optical element is a light-diffusing projection lens. Part of the second optical element is formed by multi-shot injection molding, wherein different regions (210, 220, 230) have different levels of diffraction due to the application of different grades of opalescent or diffusing materials.

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