Vehicle Headlamp Integrated Mount Member and Optical Structure
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Solution Overview
Problem
Conventional vehicle headlamps with semiconductor light sources require high precision in mounting semiconductor light emitting elements and optical parts to effectively emit and shade light, which is challenging due to the complexity of components and mounting processes.
Innovation Solution
An integrated mount member and optical member structure that allows for precise mounting of semiconductor light sources, incorporating additional reflection surfaces and shades to optimize light distribution and shading, reducing the number of parts and simplifying the mounting operation while enhancing precision and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If semiconductor light emitting elements and optical parts are mounted separately with multiple components, then the light distribution can be controlled, but the mounting precision becomes difficult to achieve and the device complexity increases
Solution Approach 1:
The patent combines the mount member and optical member into a single integrated component. The mount member includes both the mounting function for the semiconductor light emitting element and the optical function for light distribution control. This integration eliminates the need for separate optical parts, achieving high mounting precision while reducing device complexity.
Solution Approach 2:
The mount member is designed to perform multiple functions simultaneously: mechanical mounting of the light emitting element, optical reflection of light, and light distribution control. By making the mount member universal, the patent reduces the number of components needed while maintaining precise light control capabilities.
2Ease of manufacture
If multiple separate components are used for mounting and optical processing, then the light distribution pattern can be controlled, but the number of parts increases and manufacturing cost increases
Solution Approach 1:
The integration of mount member and optical member into one component directly reduces the total number of parts. This merging eliminates the need for separate optical parts, simplifying the bill of materials and reducing manufacturing costs associated with multiple components and their assembly.
Solution Approach 2:
The multi-functional mount member performs both mounting and optical processing in a single component, reducing the quantity of parts needed. This universality simplifies manufacturing processes and reduces overall manufacturing cost by eliminating the need to produce, manage, and assemble multiple separate components.
3Manufacturing precision
If conventional mounting methods are used with separate components, then the structure is simple, but the relative position between light source and optical member cannot be controlled with high precision
Solution Approach 1:
By merging the mount member and optical member into one integrated component, the patent ensures that the relative position between the light source and optical processing surfaces is precisely controlled through the integrated structure's design. This eliminates positioning errors that would occur with separate components, achieving high manufacturing precision without requiring complex alignment mechanisms.
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 integrated structure enables high-precision optical processing of light from semiconductor sources, effectively utilizing otherwise invalid light, reducing manufacturing costs, and improving light distribution patterns with reduced part complexity and increased efficiency.
Implementation Method 1
the light that is directly radiated from the light emitting chip of the semiconductor-type light source forward of the vehicle is reflected on an additional reflection surface of the optical member
Data Source
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AI summary
A vehicle headlamp according to the present invention is provided with: a semiconductor-type light source 5U; a reflector 3; a holder 6; a mount member 70U; and a light shading member 12U which has first additional reflection surfaces 15U, 15U as optical members. The mount member 70U and the light shading member 12U that has the first additional reflection surfaces 15U, 15U form an integrated structure. As a result, the vehicle headlamp according to the present invention is capable of mutually mounting, with high precision, a semiconductor-type light source 5U and the light shading member 12U that has the first additional reflection surfaces 15U, 15U as the optical members.