Elastic Retroreflector for Curved Headlight Surfaces

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Solution Overview

Problem

Existing retroreflectors based on triple mirrors face difficulties in being affixed to curved surfaces, particularly those with complex curvatures like spheroid, toroidal, ellipsoidal, or hyperbolic shapes, and require separate foils and adhesives, which are not easily integrated into headlight components.

Innovation Solution

A retroreflector composed of triple mirrors cast in optical silicone, allowing for easy molding and affixation to curved surfaces, including those with complex geometries, without the need for separate foils or adhesives, utilizing injection molding with specific curing conditions to maintain optical and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rigid triple mirrors are used for retroreflection, then retroreflection effectiveness is improved, but ease of affixation to curved surfaces deteriorates

Engineering Contradiction:

Improveretroreflection effectivenessVSAvoidease of affixation to curved surfaces

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent applies this principle by replacing rigid triple mirror structures with flexible retroreflector foils that can be conformally affixed to curved surfaces. The foil contains embedded triple mirrors that maintain their retroreflective function while allowing the overall structure to flex and adapt to complex geometries including spheroid, toroidal, ellipsoidal, and hyperbolic curvatures.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent applies this principle by creating a composite structure that combines flexible substrate material with embedded triple mirror elements. This composite foil integrates the rigidity needed for retroreflection with the flexibility needed for conformal attachment to curved surfaces, eliminating the need for separate foils and adhesives.

Inventive Principle:

Principle #40Composite materials

2Reliability

If separate foils and adhesives are used for retroreflection on curved surfaces, then retroreflection functionality is achieved, but device complexity increases

Engineering Contradiction:

Improveretroreflection functionalityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies this principle by merging the retroreflector foil and adhesive layers into a single integrated composite structure. The foil contains both the flexible substrate and the embedded triple mirrors, eliminating the need for separate components and simplifying the overall device architecture while maintaining retroreflection functionality on curved surfaces.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If retroreflectors are produced without elastic material, then manufacturing precision is improved, but adaptability to curved surfaces deteriorates

Engineering Contradiction:

Improvemanufacturing precisionVSAvoidadaptability to curved surfaces

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies this principle by using an elastic silicone material as the substrate for the retroreflector foil. This elastic material allows the foil to be stretched and conformally attached to complex curved surfaces during installation, while the embedded triple mirrors maintain their precise geometric relationships to ensure accurate retroreflection functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

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 production of retroreflectors that are temperature-resistant, maintain optical properties across a wide range, and can be easily adapted to curved surfaces, including those with two-directional curvatures, enhancing their applicability in lighting systems like motor vehicle headlights.

Implementation Method 1

Enables the production of retroreflectors that are temperature-resistant, maintain optical properties across a wide range

Methodology Applied

Scientific EffectTemperature resistance:

Implementation Method 2

The term retroreflector should be understood to mean optical elements that guide incident light that comes in at a specific angle range back to the light source

Methodology Applied

Scientific EffectRetroreflection: Retroreflector

Implementation Method 3

A retroreflector generally comprises a plurality of such triples... consists, in this regard, of three surfaces that stand essentially perpendicular to one another

Methodology Applied

Scientific EffectMultiple internal reflection: Reflection

Implementation Method 4

utilizing injection molding with specific curing conditions to maintain optical and mechanical properties

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS12138873B2Elastic retroreflector

Publication Date: 2024.11.12 GUBELA HANS ERICH

AI summary

A retroreflector includes an arrangement of triples, each having three side surfaces, which are disposed in the manner of a cube corner and stand approximately perpendicular on one another. The retroreflector can be produced from a carrier material by injection molding. An optical silicone resin is used as the carrier material. The retroreflector is based on triple mirrors that are both easily unmolded from a die and easily applied to curved surfaces even after unmolding or are usable for reflection of ultraviolet light.