Front Light Module Toroidal Lens Volume Reduction
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Solution Overview
Problem
Existing front light modules for headlamps have a large volume due to the use of reflectors, making it difficult to achieve a wide front light distribution below the horizontal zero line while minimizing installation space.
Innovation Solution
The use of collimator lens elements with differing light emitting surfaces, including a rotationally symmetrical surface and a toroidal surface section, which deflects the light distribution downwards, allowing for a reduced module size and low installation height, along with a scatter plate for horizontal light scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a reflector is used in the front light module, then the light distribution can be generated, but the module volume becomes relatively large
Solution Approach 1:
The patent extracts and removes the reflector from the optical system, replacing it with collimator lens elements that have specifically designed light emitting surfaces. This extraction eliminates the bulky reflector component while maintaining the light distribution function through the lens elements' specialized surfaces.
Solution Approach 2:
The patent replaces the mechanical reflector system with an optical lens-based system. The collimator lens elements with their specifically designed light emitting surfaces (including toroidal surfaces) provide the light distribution function that previously required a mechanical reflector, thereby reducing volume.
2Length of stationary object
If the installation height is reduced, then more installation space is saved, but achieving a wide front light distribution below the horizontal zero line becomes more difficult
Solution Approach 1:
The patent applies local quality by designing the light emitting surfaces of the collimator lens elements with specific local geometries. The toroidal light emitting surface sections are positioned in lower areas of the lens elements to deflect light downwards, creating the required wide front light distribution even at reduced installation heights.
Solution Approach 2:
The patent utilizes curved surfaces, specifically toroidal light emitting surface sections, to deflect light downwards. The toroidal geometry with its specific curvature properties enables the light to be directed at the required angles, achieving a wide front light distribution below the horizontal zero line while maintaining compact installation height.
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 configuration achieves a wide front light distribution that meets statutory values while minimizing the module's dimensions and installation height, enabling a more compact and effective lighting solution.
Implementation Method 1
a second collimator lens element features a light emitting surface section and a toroidal light emitting surface section. The toroidal second light emitting surface section can advantageously effect a vertical deflection downwards of the front light distribution.
Implementation Method 2
a scatter plate with a plurality of cylindrical surfaces running in a vertical direction is provided for in the main radiation direction of the front light module in front of the collimator lens elements. Advantageously, the scatter plate makes it possible to achieve in a cost effective manner a horizontal scatter of the light beam emitted
Data Source
AI summary
A front light module for a headlamp is provided, with a light source unit containing a number of light sources, and with an optical unit featuring a lens for generating a front light distribution (LV). The optical unit features a number of collimator lens elements arranged adjacent to each other. A first collimator lens element features a rotationally symmetrical light emitting surface and a second collimator lens element features a rotationally symmetrical light emitting surface section and a toroidal light emitting surface section.