Automotive Headlamp Integrated Low High Beam Assembly
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Solution Overview
Problem
Existing bi-functional automotive headlamps require significant space for multiple light sources and reflectors, limiting styling options and performance, especially in low-beam mode, and are less efficient compared to reflector headlamps.
Innovation Solution
A bi-functional headlamp system with an integrated low and high-beam assembly using a single reflector and two solid-state light engines, where the first light engine emits light for a low-beam pattern and the second light engine emits light through an aperture in the reflector for a high-beam pattern, reducing the overall package size and enhancing performance and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple light sources are used for low and high beam functions, then bi-functional capability is achieved, but the space required and device complexity increase
Solution Approach 1:
The patent combines multiple light sources (halogen and LED) into a single headlamp assembly with shared optical components. The halogen bulb provides both low and high beam functions through selective filtering, while the LED array supplements specific beam patterns. This merging approach achieves bi-functional capability while reducing overall headlamp volume compared to completely separate low-beam and high-beam assemblies.
Solution Approach 2:
The halogen bulb serves multiple functions by using a single light source that can produce both low-beam and high-beam patterns through the use of a colored filter wheel. The filter wheel can rotate to select different filter positions, allowing the same bulb to provide different beam types. This multi-functionality reduces the number of separate light sources needed, thereby reducing space requirements.
2Volume of moving object
If projector headlamps are used, then space is reduced, but styling options are limited and performance is lower compared to reflector headlamps
Solution Approach 1:
The patent merges the advantages of projector headlamps (compact size) with reflector headlamps (styling flexibility and performance) by using a hybrid optical system. The assembly includes both a reflector for the halogen bulb and projector lenses for the LED array. This combination allows the headlamp to maintain a compact form factor while achieving the styling flexibility and optical performance characteristics of traditional reflector systems.
3Adaptability or versatility
If multiple discrete light sources are used, then low and high beam functions are achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The halogen bulb serves as a universal light source that can produce both low-beam and high-beam patterns through the filter wheel mechanism. This reduces the need for manufacturing multiple separate bulbs and their associated mounting structures. The single bulb design simplifies the manufacturing process while maintaining the ability to provide different beam patterns through optical filtering.
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 compact bi-functional headlamp design with improved performance and styling flexibility, meeting regulatory standards while reducing component complexity and manufacturing costs.
Implementation Method 1
a reflector having a light collecting region and an aperture defined therein. The light collecting region of the reflector is adapted to receive and reflect visible light emitted by the first solid-state light source
Data Source
AI summary
An automotive headlamp (12) having first and second solid-state light sources (44, 46) and a reflector (26) having a light collecting region (28) and an aperture (40) defined therein. The light collecting region (28) of the reflector (26) is adapted to receive and reflect light emitted by the first solid-state light source (44) in a first illumination pattern. The second solid-state light source (46) is adapted to emit light through the aperture (40) in a second illumination pattern.