Small-opening low beam module system

Abstract

The utility model provides a small-opening low-beam module system which comprises a low-beam lens body, a low-beam light source module, a low-beam main light type total reflection module, a low-beam auxiliary light type total reflection module and a low-beam light inlet lens module are arranged at the light inlet end of the low-beam lens body, and a low-beam light outlet lens module is arranged at the light outlet end of the low-beam lens body. A cut-off line area is formed between the low-beam main light type total reflection module and the low-beam auxiliary light type total reflection module; the low-beam main light type total reflection module and the low-beam auxiliary light type total reflection module are located on the upper side and the lower side of the cut-off line area respectively. A traditional low beam optical system is optimized and simplified into one part which is only provided with the light inlet face, the total reflection face and the light outlet face, and the design of a module with an extremely small opening can be achieved.

Description

Technical Field

[0001] This utility model relates to the field of automotive lighting technology, specifically to a small-aperture low beam module system, and more particularly to a minimally simplistic small-aperture low beam module system. Background Technology

[0002] The automotive lighting industry is currently highly competitive, with traditional optical designs struggling to meet increasingly stringent requirements in terms of performance, cost, and styling. Due to the demands of styling design, the design of ultra-small aperture modules has become a major challenge for headlights due to low efficiency, complex components, and difficulties in mass production. Traditional optical systems, with their numerous and large components, often sacrifice luminous efficiency to achieve the performance of ultra-small aperture modules through sheer quantity, resulting in significant waste. Therefore, designing ultra-small aperture modules has become a key technological challenge.

[0003] This invention provides a minimalist design for a small-aperture low beam module system that can solve the problem of balancing the optical performance and cost of automotive lights, and offers a new design approach for future small-aperture module designs. Utility Model Content

[0004] In view of the deficiencies in the existing technology, the purpose of this utility model is to provide a small-aperture low beam module system.

[0005] According to the present invention, a small-aperture low beam module system includes: a low beam lens body, wherein the light-incident end of the low beam lens body is provided with a low beam source module, a low beam main beam total internal reflection module, a low beam auxiliary beam total internal reflection module and a low beam incident lens module, and the light-outcident end of the low beam lens body is provided with a low beam exit lens module.

[0006] A cutoff line region is formed between the low beam main beam total internal reflection module and the low beam auxiliary beam total internal reflection module; the low beam main beam total internal reflection module and the low beam auxiliary beam total internal reflection module are respectively located on the upper and lower sides of the cutoff line region;

[0007] Light is emitted from the low beam source module, passes through the low beam incident lens module, and enters the low beam lens body. Within the low beam lens body, a portion of the light reaches the low beam main beam total internal reflection module for total internal reflection and exits through the low beam exit lens module, forming the low beam main beam pattern below the cutoff line region. The other portion of the light reaches the low beam auxiliary beam total internal reflection module for total internal reflection and exits through the low beam exit lens module, forming a three-zone beam pattern above the cutoff line region.

[0008] Preferably, the cutoff line region includes: a matte textured surface and a cutoff line structure;

[0009] The low beam main light type total internal reflection module and the low beam auxiliary light type total internal reflection module are connected through the matte textured surface, which is used to diffuse the light that would otherwise cause stray light in the three zones to the outside of the module.

[0010] The cutoff line structure is disposed on the matte textured surface.

[0011] Preferably, the boundary of the near beam main beam type total internal reflection module includes: a first cutoff line region, a second cutoff line region, and a third cutoff line region connected in sequence;

[0012] The first cutoff region, the second cutoff line, and the third cutoff region are configured corresponding to the low beam assist total internal reflection module and are connected to the low beam assist total internal reflection module;

[0013] A cutoff inflection point is formed on the second cutoff line region, so the position of the cutoff inflection point is within ±5 degrees of the light emission angle of the near beam light source module.

[0014] Preferably, the boundary of the near beam assist optical pattern total internal reflection module includes: a first third zone region, a second third zone region, and a third third zone region connected in sequence;

[0015] The first three-zone area is set corresponding to the first cutoff line area, the second three-zone area is set corresponding to the second cutoff line area, and the third three-zone area is set corresponding to the third cutoff line area.

[0016] Preferably, the low beam main beam type total internal reflection module and the matte textured surface are located above the low beam incident lens module, and the light-incident direction of the low beam source module is from bottom to top;

[0017] The low beam auxiliary optical mode total internal reflection module is located on one side of the low beam incident lens module.

[0018] Preferably, the two focal points of the near beam output lens module are: one focal point is located at the position forming the primary near beam pattern, and the other focal point is located at the boundary of the total internal reflection module of the near beam auxiliary beam pattern.

[0019] Preferably, a signal light source module is provided on the low beam lens body corresponding to the defocus position of the low beam output lens module, and the light emitted by the signal light source module enters the low beam lens body through the signal light input lens module.

[0020] Preferably, the low beam lens body, the low beam source module, the low beam main beam total internal reflection module, the low beam auxiliary beam total internal reflection module, the low beam incident lens module, and the low beam exit lens module are integrally formed.

[0021] Preferably, the outer surface of the low-beam main beam total internal reflection module is coated with an aluminum layer;

[0022] And / or, the matte textured surface is provided with a patterned structure;

[0023] And / or, the near beam assist optical mode total internal reflection module is a planar or freeform surface;

[0024] And / or, the near beam assist optical pattern total internal reflection module is an integrally segmented patterned structure;

[0025] And / or, the outer surface of the near beam assist type total internal reflection module is coated with an aluminum layer;

[0026] And / or, the outer surface of the near beam assist total internal reflection module is provided with a textured surface;

[0027] And / or, the surface of the near-beam output lens module is provided with microstructures.

[0028] Preferably, the low beam light source module is any one of the following: single-chip, multi-chip, surface-mount LED, laser light source, or RGB light source;

[0029] When the low beam light source module is a surface-mount LED, it can be configured in any of the following ways:

[0030] Method 1: The surface-mount LEDs are integrated onto the PCBA board;

[0031] Method 2: The surface-mount LEDs are integrated on the heat sink and connected to the PCBA board via metal wires;

[0032] The material of the low beam lens body is any one of the following: polycarbonate, polymethyl methacrylate, glass, or silicone.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] 1. This utility model adopts a minimalist optical system design, placing the three zones on the low beam auxiliary light type total internal reflection module, avoiding design on the lens, thus improving the appearance consistency of the module. The low beam auxiliary light type total internal reflection module area increases the distance between the low beam source module and the low beam main light type total internal reflection module, reducing the thermal risk of the components and improving the focal length limit of the low beam main light type total internal reflection module.

[0035] 2. This utility model adopts a minimalist optical system design, integrating the light-incident surface, total reflection surface, and light-exit surface into one part, which solves the problem of small aperture module size. The maximum length is 55mm, and the minimum length is only 40mm. The size is only half that of the traditional optical system. This reduces light loss and tolerance problems caused by multiple parts and improves optical efficiency by nearly 100%.

[0036] 3. This utility model adopts a minimalist optical system design, integrating the light-incident surface, total reflection surface, and light-exit surface into one part, reducing the number of parts and molds, and lowering costs. At the same time, this facilitates modular design, enabling the low beam function to be realized through multiple modules, which can meet the requirements of different customers for good performance and shape.

[0037] 4. By adopting a minimalist optical system design, the near-light incident lens module, the near-light main light type total internal reflection module, the near-light auxiliary light type total internal reflection module, and the near-light output lens module can all be specially designed according to requirements, which improves the flexibility and adaptability of the module.

[0038] 5. This utility model can realize the functions of position light, turn signal or daytime running light by using a defocused low beam light source module. Attached Figure Description

[0039] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0040] Figure 1 A three-dimensional structural diagram of a small-aperture low beam module system;

[0041] Figure 2 A bottom view of the small-aperture low beam module system;

[0042] Figure 3 Top view and AA cross-sectional view of the small aperture low beam module system;

[0043] Figure 4 A schematic diagram of the optical principle of a small aperture low beam module system;

[0044] Figure 5 A schematic diagram illustrating the three-zone design principle of a small-aperture low beam module system;

[0045] Figure 6 This diagram illustrates the effect of different lens focal lengths on the same small aperture low beam module system.

[0046] Figure 7 A schematic diagram illustrating the optical principle design for the bright spot and beam broadening of a small-aperture near beam module system;

[0047] Figure 8 A schematic diagram of the bright spot and broadened optical performance of a small-aperture near beam module system;

[0048] Figure 9 A view of an optical system module with minimalist functionality for openings.

[0049] The diagram shows:

[0050] Low beam lens body 1; Low beam auxiliary beam pattern total internal reflection module 103

[0051] Low beam light source module 101, Zone 1 and 3 area 1031

[0052] Low beam main beam type total internal reflection module 102 Second and third zone area 1032

[0053] First cutoff line area 1021; Third zone area 1033

[0054] Second cutoff region 1022 Near beam incident lens module 104

[0055] Third cutoff area 1023, low beam output lens module 105

[0056] Cutoff line inflection point 1024, signal light source module 106

[0057] Matte leather texture 1025 signal light incident lens module 107 Detailed Implementation

[0058] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0059] Example 1:

[0060] As shown in 1-9, this embodiment provides a small-aperture low beam module system, including: a low beam lens body 1, the light-incident end of the low beam lens body 1 is provided with a low beam light source module 101, a low beam main beam total internal reflection module 102, a low beam auxiliary beam total internal reflection module 103 and a low beam incident lens module 104, and the light-outcident end of the low beam lens body 1 is provided with a low beam exit lens module 105; a cutoff line region is formed between the low beam main beam total internal reflection module 102 and the low beam auxiliary beam total internal reflection module 103; the low beam main beam total internal reflection module 102 and the low beam auxiliary beam total internal reflection module 103 are respectively located on the upper and lower sides of the cutoff line region. Light is emitted from the low beam source module 101, passes through the low beam entrance lens module 104, and enters the low beam lens body 1. Within the low beam lens body 1, a portion of the light reaches the low beam primary beam total internal reflection module 102 for total internal reflection and exits through the low beam exit lens module 105, forming the primary low beam pattern below the cutoff line region. The other portion of the light reaches the low beam auxiliary beam total internal reflection module 103 for total internal reflection and exits through the low beam exit lens module 105, forming a three-zone light pattern above the cutoff line region. The primary light pattern is below the cutoff line, and the auxiliary light pattern is above the cutoff line, and they do not interfere with each other.

[0061] The cutoff area includes: a matte textured surface 1025 and a cutoff structure; the low beam main light type total internal reflection module 102 and the low beam auxiliary light type total internal reflection module 103 are connected through the matte textured surface 1025, which is used to diffuse the light that would otherwise cause stray light in the three zones to the outside of the module; the cutoff structure is set on the matte textured surface 1025.

[0062] The low beam main light type total internal reflection module 102 and the matte textured surface 1025 are located above the low beam incident lens module 104, and the light-incident direction of the low beam light source module 101 is from bottom to top; the low beam auxiliary light type total internal reflection module 103 is located on one side of the low beam incident lens module 104.

[0063] like Figure 1 As shown, the matte textured surface 1025 is horizontally positioned. The primary low-beam total internal reflection module 102 is located above the matte textured surface 1025, and the secondary low-beam total internal reflection module 103 is located below the matte textured surface 1025. The upper boundary of the primary low-beam total internal reflection module 102 is connected to the upper wall of the low-beam lens body 1, and the lower boundary of the primary low-beam total internal reflection module 102 is connected to one boundary of the matte textured surface 1025. The upper boundary of the secondary low-beam total internal reflection module 103 is connected to the other boundary of the matte textured surface 1025, and the lower boundary of the secondary low-beam total internal reflection module 103 is connected to the lower wall of the low-beam lens body 1. The low-beam incident lens module 104 is disposed on the lower wall of the low-beam lens body 1.

[0064] The low beam lens body 1, low beam light source module 101, low beam main light type total internal reflection module 102, low beam auxiliary light type total internal reflection module 103, low beam incident lens module 104, and low beam exit lens module 105 are integrally molded structures. The low beam light source module 101 can be any of the following: single-chip, multi-chip, surface-mount LED, laser light source, or RGB light source; the material of the low beam lens body 1 can be any of the following: polycarbonate, polymethyl methacrylate, glass, or silicone.

[0065] When the low beam light source module 101 is a surface-mount LED, it can be set in any of the following ways:

[0066] Method 1: Surface mount LEDs are integrated onto the PCBA board;

[0067] Method 2: Surface mount LEDs are integrated onto the heat sink and connected to the PCBA board via metal wires;

[0068] In this embodiment, the low beam light source module 101 is a surface-mount LED. In other embodiments, other light source types can be selected according to actual needs.

[0069] The low beam output lens module 105 has two focal points: one focal point is located at the position forming the primary low beam pattern, and the other focal point is located at the boundary of the low beam auxiliary beam pattern total internal reflection module 103. A signal lamp light source module 106 is provided on the low beam lens body 1 at the defocused position corresponding to the low beam output lens module 105. The light emitted from the signal lamp light source module 106 enters the low beam lens body 1 through the signal lamp incident lens module 107.

[0070] The boundary of the low beam main light type total internal reflection module 102 includes: a first cutoff line region 1021, a second cutoff line region 1022, and a third cutoff line region 1023 connected in sequence; the first cutoff line region 1021, the second cutoff line region 1022, and the third cutoff line region 1023 are set corresponding to and connected to the low beam auxiliary light type total internal reflection module 103. A cutoff line inflection point 1024 is formed on the second cutoff line region 1022, so the position of the cutoff line inflection point 1024 is within ±5 degrees of the light emission angle of the low beam light source module 101.

[0071] The boundary of the low beam assist type total internal reflection module 103 includes: a first three-zone region 1031, a second three-zone region 1032, and a third three-zone region 1033 connected in sequence; the first three-zone region 1031 is set to correspond to the first cutoff line region 1021, the second three-zone region 1032 is set to correspond to the second cutoff line region 1022, and the third three-zone region 1033 is set to correspond to the third cutoff line region 1023.

[0072] The aperture size of the low beam output lens module 105 can be any of the following: 5mm x 5mm, 6mm x 6mm, 7mm x 7mm to 20mm x 20mm.

[0073] The outer surface of the low beam main light type total internal reflection module 102 is coated with an aluminum layer; the matte textured surface 1025 is provided with a patterned structure; the low beam auxiliary light type total internal reflection module 103 is a planar or free-form surface; the low beam auxiliary light type total internal reflection module 103 has an integrally segmented patterned structure, which is a millimeter-level fisheye pattern used for three-light design; the outer surface of the low beam auxiliary light type total internal reflection module 103 is coated with an aluminum layer; the outer surface of the low beam auxiliary light type total internal reflection module 103 is provided with a texture; the surface of the low beam output lens module 105 is provided with a microstructure, which is a nanometer or micrometer-level pattern.

[0074] Example 2:

[0075] Those skilled in the art can understand this embodiment as a more specific description of Embodiment 1.

[0076] This embodiment provides a minimalist small-aperture low beam module system design, including: a low beam source module 101, a low beam main beam total internal reflection module 102, a low beam auxiliary beam total internal reflection module 103, a low beam incident lens module 104, and a low beam exit lens module 105.

[0077] The boundary of the low beam main beam type total internal reflection module 102 includes a first cutoff line region 1021, a second cutoff line region 1022, a third cutoff line region 1023, a cutoff line inflection point 1024, and a matte textured surface 1025.

[0078] The low beam assist type total internal reflection module 103 includes a first three-zone region 1031, a second three-zone region 1032, and a third three-zone region 1033.

[0079] Because the brightest point of the low beam is near the cutoff line, the position of the cutoff line inflection point 1024 is within ±5 degrees of the light emission angle of the low beam light source module 101.

[0080] Light is emitted from the near light source module 101, then converged by the near light incident lens module 104 and enters the component.

[0081] A portion of the light reaches the near beam main beam total internal reflection module 102 and undergoes total internal reflection to form light rays A1A2. These light rays are then emitted as light rays A2A3 through the near beam output lens module 105. After reaching the 25-meter screen, the light rays form the near beam main beam pattern. The cutoff lines A, B, and C of the near beam pattern are formed by the first cutoff line region 1021, the second cutoff line region 1022, and the third cutoff line region 1023 of the boundary of the near beam main beam total internal reflection module 102. A cutoff line D corresponding to the cutoff line inflection point 1024 is also formed. The cutoff line position is adjusted by adjusting the boundary position.

[0082] Another portion reaches the near-beam auxiliary light pattern total internal reflection module 103 for total internal reflection into B1B2 rays, and is then emitted as B2B3 rays through the near-beam output lens module 105. After reaching the 25-meter screen, it forms a three-zone light pattern. The three-zone light pattern regions E, F, and G are formed by the boundaries of the near-beam auxiliary light pattern total internal reflection module 103: the first three-zone region 1031, the second three-zone region 1032, and the third three-zone region 1033. The near-beam auxiliary light pattern total internal reflection module region increases the distance between the near-beam source module 101 and the near-beam main light pattern total internal reflection module 102, reduces the thermal risk of components, and improves the focal length limit of the total internal reflection module.

[0083] Meanwhile, the matte textured surface 1025 can diffuse light that would otherwise cause stray light in the three zones outside the module, reducing the risk of exceeding regulatory limits. The low beam output lens module 105 has two focal points: one (F') at 25 meters (as required by regulations), and the other (F1) at the upper boundary of the low beam auxiliary light pattern total internal reflection module 103 (within a focal length of 60mm). Their front-to-back and vertical positions are within ±5mm. There are no restrictions on their left-to-right positions, allowing for design based on the target light pattern (bright low beam pattern, broadened low beam pattern). Additionally, a low beam source module for a signal light can be placed out of focus to function as a position light, turn signal, or daytime running light.

[0084] The minimum opening size of the low beam output lens module 105 is 5mm x 5mm, but it can also be 6mm x 6mm, 7mm x 7mm to 20mm x 20mm.

[0085] Furthermore, the focal length of the low beam main light type total internal reflection module 102 can be adjusted according to design requirements (1mm to 5mm). The smaller the focal length, the more focused the light pattern and the larger the maximum value; conversely, the more focused the light pattern and the smaller the maximum value.

[0086] Furthermore, the outer surface of the low beam main beam type total internal reflection module 102 can be plated with aluminum, thereby reducing light loss and improving optical efficiency.

[0087] Furthermore, the position and shape of the cutoff line area of ​​the low beam main beam total internal reflection module 102 are adjustable and can be designed according to different regulations and customer requirements.

[0088] Furthermore, the matte textured surface 1025 of the low beam main beam type total internal reflection module 102 can be enhanced with a patterned structure to improve its matte performance.

[0089] Furthermore, the depth of the matte textured surface 1025 of the low beam main light type total internal reflection module 102 can be adjusted according to the three-zone design requirements. If stronger energy is required, the depth is smaller, and vice versa.

[0090] Furthermore, the surface of the low beam assist type total internal reflection module 103 can be designed according to requirements, and can be a plane, a free-form surface, etc.

[0091] Furthermore, the three-zone design on the low beam assist light type total reflection module 103 area can be an overall segmented pattern, or it can be a separate design for a special area, or other three-zone designs.

[0092] Furthermore, the outer surface of the low beam assist type total internal reflection module 103 can be plated with aluminum, thereby reducing light loss and improving optical efficiency.

[0093] Furthermore, the outer surface of the low beam assist type total internal reflection module 103 can be textured to reduce stray light in the three zones.

[0094] Furthermore, the surface shape of the near beam incident lens module 104 can be adjusted according to design requirements. It can converge or diverge light, and the size of its convergence or divergence can also be adjusted by the surface shape.

[0095] Furthermore, the focal length of the low beam output lens module 105, that is, the distance to the low beam auxiliary light pattern total internal reflection module 103, can be adjusted. The smaller the distance, the higher the efficiency, the more diffused the light pattern, and the smaller the maximum value. Conversely, the larger the distance, the lower the efficiency, the more focused the light pattern, and the larger the maximum value.

[0096] Furthermore, the surface of the low beam output lens module 105 can be enhanced with microstructures to improve road surface uniformity.

[0097] Furthermore, the number, arrangement, and illumination of multiple near-beam bright spot patterns and near-beam broadening patterns in the final combination of optical systems can be adjusted according to performance requirements, design requirements, and illumination requirements.

[0098] Furthermore, the low beam light source module 101 can be a single chip, a multi-chip, or a surface-mount LED or laser light source or an RGB light source.

[0099] Furthermore, the low beam light source module 101 is configured as a surface-mount LED, which is integrated onto the PCBA or onto a heat sink. When integrated onto a heat sink, it is connected to the PCBA board via metal wires. In other embodiments, other light source types can be selected according to actual needs.

[0100] Furthermore, the material of this system can be polycarbonate (i.e., PC), polymethyl methacrylate (i.e., PMMA), glass, or silicone.

[0101] Example 3:

[0102] Those skilled in the art can understand this embodiment as a more specific description of Embodiment 1.

[0103] This embodiment provides a minimalist design for a small-aperture low beam module system. More specifically, this low beam module opening is a 5mm x 5mm thick-walled component design, such as... Figure 1 and Figure 2 As shown in the module view and top view of the minimalist small-aperture low beam system, a single minimalist low beam module system includes a low beam source module 101, a low beam main beam total internal reflection module 102, a low beam auxiliary beam total internal reflection module 103, a low beam entrance lens module 104, and a low beam exit lens module 105.

[0104] like Figure 3 and Figure 4 As shown in the top view, AA cross-sectional view, and optical principle diagram of the minimalist small-aperture low beam module system, light is emitted from the low beam source module 101, then converged by the low beam incident lens module 104 and enters the component. A portion reaches the low beam main beam total internal reflection module 102 for total internal reflection into light rays A1A2, and is emitted as light rays A2A3 through the low beam exiting lens module 105. After reaching the 25-meter screen, it forms the low beam main beam. The cutoff lines A, B, and C of the low beam main beam are formed by the first cutoff line region 1021, cutoff line 1022, and second cutoff line region 1023 of the boundary of the low beam main beam total internal reflection module 102, and form D corresponding to the cutoff line inflection point 1024. The cutoff line position is adjusted by adjusting the boundary position. Another portion reaches the near beam auxiliary light pattern total internal reflection module 103 for total internal reflection into B1B2 light rays, and is emitted into B2B3 light rays through the near beam output lens module 105. After reaching the 25-meter screen, it forms a three-zone light pattern. The three-zone light pattern regions E, F, and G are formed by the boundaries of the near beam auxiliary light pattern total internal reflection module 103: the first three-zone region 1031, the second three-zone region 1032, and the third three-zone region 1033.

[0105] Figure 3 middle, Figure 3 .1 is a top view of the small aperture low beam module system. Figure 3 .2 is Figure 3 .1 Schematic cross-sectional view along line AA.

[0106] The near beam exiting lens module 105 features two focal points: one (F') at 25 meters (as required by regulations), and the other (F1) at the upper boundary of the near beam auxiliary total internal reflection module 103, with their front-to-back positions within ±5mm. The left-to-right positions are unrestricted and can be designed according to the target beam pattern (near beam bright spot pattern, near beam broadened pattern). To reduce light loss and improve optical efficiency, the outer surface of the near beam main total internal reflection module 102 is aluminum-plated. The near beam entrance lens module improves light input efficiency. Simultaneously, the minimalist optical system within this opening reduces the module size, with a maximum length of 55mm and a minimum length of only 40mm, significantly smaller than conventional optical system designs, thus also improving light output efficiency. The integrated design reduces light loss caused by multiple components. Therefore, the efficiency of this low beam system can reach 53% when the aperture is 15mm x 15mm; 40% when the aperture is 10mm x 10mm; and 25% even when the aperture is 5mm x 5mm, which is much higher than the efficiency of other very small aperture modules (10%).

[0107] More specifically, such as Figure 4 The optical principle diagram is shown. Figure 4 Figure 1 shows a schematic diagram of light propagation in a small-aperture low beam module system. Because the brightest point of the low beam is near the cutoff line, the cutoff line should be positioned directly above the light emission from the low beam source module, within ±5 degrees of the emission angle. Therefore, the surface below the cutoff line of the low beam main beam total internal reflection module will generate stray light, affecting optical performance and regulatory requirements. Furthermore, being too close to the low beam source module can also pose a risk to the heat resistance of components. Figure 4 The light rays shown in Figure 2 illustrate the light propagation in a low beam module without an matte finish. In a traditional design, light emitted from the low beam source module passes through the low beam incident lens module and enters the thick-walled component. A portion of the light, A12, reaches the low beam main beam type total internal reflection module, while another portion, B12, reaches the sidewall below the cutoff line. Because the divergence angle near the center of the light-emitting module is relatively strong, no matter how it is designed or an absorption coating is added, it cannot be completely eliminated, thus easily generating stray light that affects regulations. Therefore, this embodiment designs a special three-zone structure, such as... Figure 4The diagram in section .3 illustrates the light propagation in a low beam module with a matte textured surface. Light rays B13 and C13, originally below the cutoff line, continue to propagate within the structure. Ray B13 assists the total internal reflection module design in positioning the light within zone B23, while unwanted light rays are diffused out onto the matte surface B'13. Ray C13, being close to the center of the low beam light source module's divergence angle, diffuses directly out through the matte surface C23. This ensures the position of the main beam cutoff line, increases the distance between the low beam light source module 101 and the main low beam total internal reflection module 102, reduces the thermal risk of components, improves the focal length limit of the main low beam total internal reflection module, and avoids the influence of stray light.

[0108] More specifically, since the low beam requires both brightness and a beam width of at least 35-45 degrees, a single low beam module cannot meet this width requirement. Therefore, multiple low beam modules need to be stacked to form a beam pattern. One part is designed with a bright spot pattern to meet the brightness requirement, while the other part is designed with a widened beam pattern to meet the width requirement. Each module needs a different widening angle design, ultimately stacked to form a beam pattern of at least 35 degrees. This implementation example... Figure 6 The diagram illustrates the effect of different lens focal lengths on the same minimalist small-aperture low beam module system. The focal length of the low beam output lens module 105, i.e. the distance to the low beam auxiliary light pattern total internal reflection module 103, can be adjusted. For example, if the focal length L2 of module 2 is smaller (35mm), the resulting light pattern 2 will have higher efficiency, a more diffuse light pattern, and a smaller maximum value. It can be used to design a broadened low beam light pattern. Conversely, if the focal length L1 of module 1 is larger (50mm), the resulting light pattern 1 will have lower efficiency, a more focused light pattern, and a larger maximum value. It can be used to design a bright spot light pattern for low beams.

[0109] Figure 6 middle, Figure 6 .1 shows a schematic diagram of two near-beam module systems with different lens focal lengths. Figure 6 .2 is Figure 6 A schematic diagram of the beam pattern formed by the two low beam module systems in .1.

[0110] More specifically, such as Figure 7The simplified optical schematic of the small-aperture low beam module system illustrates the design principles for the bright spot and beam widening. The focal position of the low beam output lens module 105 also influences the optical design. When the focal point F1 is centered (module 1.1), the beam pattern is centered (beam pattern 1.1), suitable for the low beam bright spot design. When the focal point F2 deviates from the center (module 2.1), the beam pattern also deviates from the center (beam pattern 2.2), suitable for the low beam widening design. Similarly, because the low beam bright spot requires high brightness, a larger focal length (module 1.1) results in a more focused beam pattern (beam pattern 1.1) while maintaining a centered position. Conversely, a smaller focal length (module 2.1) results in a more diffused beam pattern (beam pattern 2.1) for the low beam widening design.

[0111] Figure 7 middle, Figure 7 .1 represents two low beam module systems: one with the focus at the center position and the other with the focus off-center. Figure 7 .2 is Figure 7 A schematic diagram of the beam pattern formed by the two low beam module systems in .1.

[0112] More specifically, the low beam in this embodiment is as follows: Figure 8 A schematic diagram illustrating the brightness spot and optical performance of a minimalist small-aperture near-beam module system is shown. Figure 8 .1 and Figure 8 .4 shows the energy distribution map and uniformity grayscale map of the near-light bright spot. Figure 8 Figures 0.2 and 8.5 are the energy distribution map and uniformity grayscale map for near-light broadening 1. Figure 8 Figures 8.3 and 8.6 show the energy distribution and uniformity grayscale of the near beam broadening 2. In this embodiment, the focal position of the near beam output lens module 105 is horizontally adjusted. When the focal point is in the center, the beam pattern center is at 0 degrees. When adjusted 3mm to the right, the center of the broadened beam pattern shifts 10 degrees to the left, and the left boundary of the beam pattern reaches -25 degrees, which is near beam broadening 1. When the focal point shifts 5mm to the right, the center of the broadened beam pattern shifts 20 degrees to the left, and the left boundary of the beam pattern reaches -35 degrees, which is near beam broadening 2. The right-side beam pattern uses the same design method, thus meeting the basic angular requirements for near beam broadening. Multiple modules can be combined to form a near beam pattern, offering great flexibility and enabling the fulfillment of different customer styling and lighting requirements. Figure 9 As shown, a low beam light source module for a traffic light is placed out of focus, which can realize the functions of position light, turn signal or daytime running light.

[0113] More specifically, the detailed design of the three-zone low beam is as follows: Figure 5As shown, the three-zone light pattern regions E, F, and G are formed by the boundaries of the near-beam auxiliary light pattern total internal reflection module 103: the first three-zone region 1031, the second three-zone region 1032, and the third three-zone region 1033. The surface of the near-beam auxiliary light pattern total internal reflection module 103 can be designed according to requirements; it can be a plane, a freeform surface, etc. Furthermore, the surface can be entirely divided to create patterns, or specific areas can be designed separately, among other three-zone designs. The outer surface of the near-beam auxiliary light pattern total internal reflection module 103 is partially aluminum-plated to reduce light loss and improve optical efficiency. Simultaneously, some parts of the outer surface need to have a textured finish to reduce stray light in the three zones. The three zones are designed to avoid being located on the lens, improving the overall appearance consistency of the module.

[0114] Figure 5 middle, Figure 5 .1 is a schematic diagram highlighting the three regions of the low beam assist total internal reflection module. Figure 5 .2 is a schematic diagram highlighting the three-zone light pattern and the cutoff line light pattern formed by the three-zone region and the cutoff line region. Figure 5 .3 is a schematic diagram showing the overall surface segmentation and patterning of the low beam auxiliary light type total internal reflection module. Figure 5 .4 is a schematic diagram of the partial aluminum plating on the outer surface of the low beam auxiliary light type total internal reflection module.

[0115] This embodiment integrates the light-incident surface, total internal reflection surface, and light-exit surface into a single component. This embodiment enables an ultra-small aperture module. The focal point of the module in this embodiment is not restricted in its left or right position. The module in this embodiment features a unique three-zone structure.

[0116] This embodiment optimizes and simplifies a traditional low-beam optical system into a single component with only an incident light surface, a total internal reflection surface, and an exit light surface, enabling the design of a module with an extremely small aperture. The low-beam optical system includes a low-beam incident lens module, a low-beam primary beam total internal reflection module, a low-beam auxiliary beam total internal reflection module, and a low-beam exit lens module, along with a low-beam light source module. The low-beam primary beam total internal reflection module achieves the cutoff line pattern for low beams, and the low-beam auxiliary beam total internal reflection module meets the regulatory requirements for the three light zones; their components are then combined to form the final low-beam pattern. The area of ​​the low-beam auxiliary beam total internal reflection module increases the distance between the low-beam light source module 101 and the low-beam primary beam total internal reflection module 102, reducing the thermal risk of the component and improving the focal length limit of the low-beam primary beam total internal reflection module. The simplified system is only about half the size of the traditional system, significantly reducing the size of the optical system and improving the optical efficiency. Simultaneously, the low-beam incident lens module improves the incident light efficiency, making the overall efficiency of this system more than twice that of the traditional optical system. The integrated design reduces component tolerances, improves the stability of the optical system, facilitates the design of small-aperture modules, and lowers module costs. This low beam system module can achieve bright spot patterns and broadened low beam patterns, with multiple matching combinations forming the desired low beam pattern, offering high flexibility and enabling different shapes. Combined with software control, it can create welcoming, rhythmic, and other lighting effects. Simultaneously, a defocused low beam light source module for a signal light can function as a position light, turn signal, or daytime running light. If the signal light light source module uses RGB LEDs, a colored lighting visual effect can be achieved.

[0117] This invention optimizes and simplifies the traditional near-beam optical system into a single component, consisting only of an incident light surface, a total reflection surface, and an exit light surface, enabling the design of an extremely small aperture module.

[0118] This invention can be configured to generate multiple light distributions, each of which is of a different type. The type of each light distribution is any one of the following: low beam lighting, high beam lighting, adaptive low beam lighting, ADB high beam lighting, corner fog light lighting, urban road mode lighting, rural road mode lighting, highway mode lighting, curve mode lighting, rain and fog mode lighting, position signal light, turn signal light, daytime running light, welcome light, ambient light, etc.

[0119] This utility model can also be combined in various ways to achieve a through-light effect according to various design requirements.

[0120] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0121] The specific embodiments of this utility model have been described above. It should be understood that this utility model is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the substantive content of this utility model. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A small opening low beam module system, characterized in that, The application relates to a low-beam lens body (1), the light-in end of the low-beam lens body (1) is provided with a low-beam light source module (101), a low-beam main light type total reflection module (102), a low-beam auxiliary light type total reflection module (103) and a low-beam light-in lens module (104), and the light-out end of the low-beam lens body (1) is provided with a low-beam light-out lens module (105); a cutoff line area is formed between the low-beam main light type total reflection module (102) and the low-beam auxiliary light type total reflection module (103); the low-beam main light type total reflection module (102) and the low-beam auxiliary light type total reflection module (103) are respectively located on the upper and lower sides of the cutoff line area; light is emitted from the low-beam light source module (101), enters the low-beam lens body (1) through the low-beam light-in lens module (104), and the light entering the low-beam lens body (1) is totally reflected at the low-beam main light type total reflection module (102) and the low-beam auxiliary light type total reflection module (103) and is emitted through the low-beam light-out lens module (105), thereby forming a low-beam main light type below the cutoff line area and a three-zone light type above the cutoff line area. The cutoff line area comprises a light-absorbing skin surface (1025) and a cutoff line structure; The low-beam main light type total reflection module (102) and the low-beam auxiliary light type total reflection module (103) are connected through the light-absorbing skin surface (1025), and the light-absorbing skin surface (1025) is used for dispersing light originally causing three-zone stray light outside the module; The cutoff line structure is arranged on the light-absorbing skin surface (1025).

2. The small opening low beam module system of claim 1, wherein, The boundary of the low-beam main light type total reflection module (102) comprises a first cutoff line area (1021), a second cutoff line area (1022) and a third cutoff line area (1023) connected in sequence; The first cutoff line area (1021), the second cutoff line area (1022) and the third cutoff line area (1023) are arranged corresponding to the low-beam auxiliary light type total reflection module (103) and are connected with the low-beam auxiliary light type total reflection module (103); A cutoff line inflection point (1024) is formed on the second cutoff line area (1022), so that the position of the cutoff line inflection point (1024) is within the light-out angle of the low-beam light source module (101) plus or minus 5 degrees.

3. The small opening low beam module system of claim 1, wherein, The low-beam auxiliary light type total reflection module (103) comprises a first three-zone area (1031), a second three-zone area (1032) and a third three-zone area (1033) connected in sequence; The first three-zone area (1031) is arranged corresponding to the first cutoff line area (1021), the second three-zone area (1032) is arranged corresponding to the second cutoff line area (1022), and the third three-zone area (1033) is arranged corresponding to the third cutoff line area (1023). ​ 4. The small opening low beam module system of claim 3, wherein, ​ ​ 5. The small opening low beam module system of claim 2, wherein, The low-beam main light type total reflection module (102) and the low-beam light extinction skin surface (1025) are located above the low-beam light entering lens module (104), and the light entering direction of the low-beam light source module (101) is from below to above; The low-beam auxiliary light type total reflection module (103) is located on one side of the low-beam light entering lens module (104).

6. The small opening low beam module system of claim 1, wherein, Two focal points of the low-beam light exiting lens module (105): one focal point is located at a position forming a low-beam main light type, and the other focal point is located at a boundary of the low-beam auxiliary light type total reflection module (103).

7. The small opening low beam module system of claim 6, wherein, The low-beam lens body (1) is provided with a signal lamp light source module (106) corresponding to the defocus position of the low-beam light exiting lens module (105), and the light emitted by the signal lamp light source module (106) enters the low-beam lens body (1) through a signal lamp light entering lens module (107).

8. The small opening low beam module system of claim 1, wherein, The low-beam lens body (1), the low-beam light source module (101), the low-beam main light type total reflection module (102), the low-beam auxiliary light type total reflection module (103), the low-beam light entering lens module (104) and the low-beam light exiting lens module (105) are integrally formed.

9. The small opening low beam module system of claim 5, wherein, The outer surface of the low-beam main light type total reflection module (102) is plated with an aluminum layer; And / or, the low-beam light extinction skin surface (1025) is provided with a pattern structure; And / or, the low-beam auxiliary light type total reflection module (103) is a plane or a free-form surface; And / or, the low-beam auxiliary light type total reflection module (103) is an integral segmentation pattern structure; And / or, the outer surface of the low-beam auxiliary light type total reflection module (103) is plated with an aluminum layer; And / or, the outer surface of the low-beam auxiliary light type total reflection module (103) is provided with a skin; And / or, the surface of the low-beam light exiting lens module (105) is provided with a microstructure.

10. The small opening low beam module system of claim 1, wherein, The low-beam light source module (101) is any one of the following: single-chip, multi-chip, patch LED, laser light source, RGB light source; When the low-beam light source module (101) is a patch LED, any one of the following modes is adopted: Mode one: the patch LED is integrated on a PCBA board; Mode two: the patch LED is integrated on a heat sink, and is connected to a PCBA board through a metal wire; The material of the low-beam lens body (1) is any one of the following: polycarbonate, polymethyl methacrylate, glass, and silica gel.

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