Baffled Tri-Region Optic for Adaptive Headlamp Cost Reduction
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Solution Overview
Problem
Existing adaptive front lighting systems for vehicles are expensive due to the need for multiple high-quality glass lenses and complex optics, limiting their implementation to high-end vehicle models.
Innovation Solution
A baffled tri-region optic lens system that uses a single LED array and aspherical lenses made from inexpensive transparent plastic, such as PMMA, to create a rectangular field of illumination, reducing heat dissipation and manufacturing costs by eliminating the need for multiple LED chips and complex optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple high-quality glass lenses and complex optics are used to achieve adaptive front lighting, then the lighting performance and focus precision are improved, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent merges multiple separate glass lenses into a single integrated optic component. The single optic incorporates multiple optical regions with different refractive indices directly within one piece, eliminating the need for separate stacked lenses and reducing assembly complexity while maintaining focus precision.
Solution Approach 2:
The patent uses composite optical materials with different refractive indices within a single optic structure. By incorporating regions of varying refractive indices in one component, it achieves the optical separation and focusing effects previously requiring multiple separate glass lenses, thereby reducing device complexity.
2Manufacturing precision
If multiple high-quality glass lenses are used to achieve correct focus, then the lighting performance is improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple expensive high-quality glass lenses into a single optic, reducing the total number of precision-manufactured components. This merging reduces manufacturing cost while maintaining focus precision through integrated optical design.
Solution Approach 2:
The patent replaces expensive high-quality glass lenses with a single optic that can be manufactured from less expensive materials. While the material may be less durable than glass, it achieves the required optical performance at lower cost, making adaptive lighting accessible to non-high-end vehicles.
3Illumination intensity
If multiple LED chips are used to provide sufficient illumination, then the lighting intensity is improved, but the heat dissipation requirements and device complexity increase
Solution Approach 1:
The patent merges multiple LED chips into a single LED array integrated within one optic. This consolidation maintains sufficient illumination intensity while reducing the number of separate heat-generating components, thereby simplifying heat dissipation management.
Solution Approach 2:
The single LED array performs the lighting function that previously required multiple separate LED chips. By making the LED array multi-functional to replace multiple chips, it reduces heat dissipation requirements and device complexity while maintaining adequate illumination 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
Enables the economical implementation of adaptive front lighting systems in non-high-end vehicles by reducing manufacturing costs and heat dissipation requirements, allowing for selective dimming of light regions based on detected vehicles.
Implementation Method 1
The lens is configured to transform or focus an unfocused field of illumination of an array of LEDs into the approximately rectangular field of illumination
Implementation Method 2
The baffle reduces or obstructs light spreading from any of the light-transmissive first, second, and third optical regions to any other light-transmissive first, second, and third optical regions
Data Source
AI summary
An automotive lighting system (41) includes an automotive lamp having an LED array (14) and a lens (34). The lens (34) images a square field of illumination (101) into rectangular field of illumination (48) to support adaptive front lighting in an automotive environment (28). The lens (34) includes light-transmissive first, second, and third regions (64, 66, 68), and a baffle (70) adapted to obstruct light from spreading between the light-transmissive first, second, and third regions (64, 66, 68). The baffle (70) is disposed between the LED array (14) and light receiving surfaces (98, 104, 110) of the light-transmissive first, second, and third regions (64, 66, 68). The lens (34) enables imaging of an approximately rectangular field of illumination (48) from a single chip (12), reducing cost and cooling needs of adaptive front lighting systems.