Condensing and Collimating Optical Platform for Automotive Lighting
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Solution Overview
Problem
Current automotive lighting systems are inefficient in utilizing all light generated by a light source, with most systems utilizing only about 50% of the light due to poor collimation and light loss, leading to larger packaging, increased complexity, and higher power consumption.
Innovation Solution
An optical design that utilizes 100% of the light emission from a 120-degree source viewing angle by employing a combination of condensing lenses and a collimator, such as a plano-convex refracting lens, to create a high-intensity, collimated light beam with a compact packaging size, using materials like polycarbonate and incorporating features like lenticular flutes and wedged surface patches to achieve efficient light projection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If reflector designs are used to direct light, then light can be projected forward, but only about 50% of light is effectively utilized due to spill light and central obscuration
Solution Approach 1:
The optical system is divided into multiple functional zones: a central refracting region for collecting on-axis light, an intermediate reflecting region for redirecting off-axis light, and an outer refracting region for capturing peripheral light. This segmentation allows each zone to optimize light collection from different angular ranges, collectively achieving near-100% light utilization
Solution Approach 2:
The optical system employs a hybrid composite design combining refracting elements (lenses) and reflecting elements (mirrors) in a single integrated structure. The refracting portions use materials with specific refractive indices to bend and focus light, while the reflecting portions use highly reflective coatings to redirect light, creating a composite optical system that overcomes the limitations of purely reflective or purely refractive designs
2Illumination intensity
If reflector designs with parabolic mirrors are used, then light can be reflected in defined directions, but larger focal lengths are required resulting in larger packaging envelopes
Solution Approach 1:
The patent transitions from traditional two-dimensional parabolic mirror surfaces to a three-dimensional integrated optical structure with varying curvature radii in different zones. The optical system uses surfaces with different curvature radii (first, second, and third curvature radii) arranged in concentric zones, allowing light control in multiple spatial dimensions simultaneously, achieving compact packaging while maintaining beam directionality
Solution Approach 2:
The optical system employs a nested concentric zone structure where the central refracting zone, intermediate reflecting zone, and outer refracting zone are arranged in nested circular patterns around the light source. This nested arrangement allows multiple optical functions to be packed into a compact cylindrical envelope, minimizing packaging volume while maintaining effective light control
3Illumination intensity
If refracting systems are used to collimate light, then light can be sharply collimated over extended field of view, but transmission loss occurs due to Fresnel Reflections and limited numerical aperture
Solution Approach 1:
The optical system segments the light collection function across three distinct zones with different optical mechanisms. The central and outer refracting zones use lens surfaces with specific curvature radii to collimate light from different angular ranges, while the intermediate reflecting zone handles light that would otherwise be lost. This segmentation allows each zone to operate at optimal angles, minimizing Fresnel reflections and maximizing transmission
Solution Approach 2:
The patent optimizes transmission by carefully selecting and varying key parameters: the curvature radii of different optical surfaces (first, second, and third curvature radii), the refractive indices of lens materials, and the angular acceptance of each zone. By changing these parameters across different zones, the system minimizes Fresnel reflection losses and maximizes light transmission while maintaining sharp collimation
4Illumination intensity
If multiple light sources are used to achieve desired optical function, then light output can be increased, but power efficiency decreases and complexity in assembly and thermal management increases
Solution Approach 1:
The patent introduces an intermediary optical system that acts as a light management mediator between the LED source and the external environment. The integrated refracting-reflecting structure serves as an intermediary that redirects and focuses light that would otherwise be wasted, effectively increasing optical output without adding more light sources. This intermediary optical train maximizes utilization of light from the single LED, improving power efficiency while maintaining high optical power output
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
This design achieves higher optical power output, higher beam intensity, and smaller packaging sizes while reducing electrical power consumption, effectively addressing the inefficiencies in existing systems by ensuring nearly all light is utilized, resulting in improved performance across various lighting applications.
Implementation Method 1
at least one condensing lens in the light path of the light source and positioned relative to the light source to encompass the light source and condenses the light into a light beam
Implementation Method 2
a collimator shaped and positioned relative to the condensing lens or lenses to encompass the entire area of the light beam
Implementation Method 3
The invention is configured such that a simple change in surface geometry can diverge collimation along either an azimuthal or elevation axis enabling the ability to make a beam pattern unique to a given forward projecting illumination application
Data Source
AI summary
A forward projecting condensing and collimating optical platform enables the ability to more effectively utilize the light generated from a Lambertian light source. The optical system can effectively utilize light emitted from a 120-degree source viewing angle over a substantially large extended field of view. The optical system can project a high intensity light in a smaller packaging envelope. The optical design can be used for generation of hi-Intensity spot beams, fog lamps, head lamp low beams, head lamps, hi beams, a driving beam, and the like, while operating at a lower power input to equivalent optical systems.