Asymmetric Headlight Projector Units for Unified Illumination
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Solution Overview
Problem
Current headlight assemblies for vehicles require multiple optical projectors with different prescriptions to achieve the desired illumination pattern, leading to increased costs due to the need for special tools and multiple components, and are unable to provide both the necessary spread and high intensity in a single module.
Innovation Solution
A headlight assembly comprising two projector units with angled light sources and imaging lens assemblies, each with a plurality of pixel light sources, which overlap to create a combined illumination pattern with a smooth transition, achieving higher intensity in the overlapping region while maintaining the required spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple optical projectors with different prescriptions are used to achieve desired illumination pattern, then the illumination quality and spread are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The illumination pattern is segmented into multiple zones (central high-intensity region and peripheral spread regions) that are illuminated by different projector units with different optical prescriptions. Each projector unit is responsible for a specific portion of the overall pattern, allowing optimization of each segment while managing overall system complexity.
Solution Approach 2:
Multiple projector units with different optical characteristics are merged into a single headlight assembly, with their illumination patterns overlapping to create a unified light distribution. The overlapping regions combine to provide both the required spread and high intensity in central areas.
2Illumination intensity
If multiple optical projectors with different prescriptions are used to achieve desired illumination pattern, then the illumination quality is improved, but the manufacturing cost increases
Solution Approach 1:
The headlight assembly is segmented into multiple projector units that can be manufactured separately using standardized processes, then assembled together. This segmentation allows each unit to be optimized for its specific function while using common manufacturing techniques across all units.
Solution Approach 2:
The projector units are designed with universal mounting interfaces and standardized components that allow them to be manufactured using the same tooling and assembly processes, reducing the need for specialized manufacturing equipment despite the different optical prescriptions.
3Device complexity
If a single projector unit is used, then the device complexity is reduced, but the ability to provide both spread and high intensity is compromised
Solution Approach 1:
Different regions of the illumination pattern have different optical qualities: the central region requires high intensity with narrow spread, while peripheral regions require wider spread with lower intensity. Each projector unit is optimized for its specific region, providing locally appropriate optical characteristics.
Solution Approach 2:
The system adds the dimension of angular orientation by positioning projector units at different angles relative to the headlight axis. This angular dimension allows each projector to contribute to different portions of the illumination pattern while working together to provide both spread and intensity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for a single module to meet both high beam intensity and spread requirements, reducing costs and complexity while providing a unified illumination pattern that appears to originate from a single source.
Implementation Method 1
a first imaging lens assembly overlying the first light source and configured to focus and direct light from the first light source to produce a first far-field illumination pattern
Implementation Method 2
The second projector unit is angled relative to the first projector unit to cause the second far-field illumination pattern to partially overlap the first far-field illumination pattern to define an overlapping region, with the first projector unit and the second projector unit being operable together to produce region of higher intensity within the overlapping region
Data Source
AI summary
A headlight assembly for a vehicle includes: first and second projector units each including a light source and an imaging lens assembly overlying the light source and configured to focus and direct light from the light source to produce a corresponding far-field illumination pattern. The light sources of each of the first and second projector units each include a plurality of pixel light sources. The second projector unit is angled relative to the first projector unit to cause the second far-field illumination pattern therefrom to partially overlap the first far-field illumination pattern from the first projector unit and to define an overlapping region and a combined illumination pattern having a smooth transition across boundaries where the far-field illumination patterns extends beyond the overlapping region, and causing the combined illumination pattern to appear to originate from a single source.