Vehicle Headlamp Lens Corrugated Profiling for Traffic Sign Detection
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Solution Overview
Problem
The existing headlamp technologies for vehicles with micro-optical elements to detect overhead traffic signs are costly due to the high manufacturing costs of uniform micro-optical structures.
Innovation Solution
The use of corrugated profiling with arched projections and outlet sections on the lens surfaces for scattering light, creating a continuous surface without edges, which allows for the detection of overhead traffic signs while reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform micro-optical elements are used to detect overhead traffic signs, then the detection function is achieved, but the manufacturing costs increase significantly
Solution Approach 1:
The patent applies local quality by implementing corrugated profiling only in specific sub-areas of the lens surface rather than uniformly across the entire surface. The corrugations are strategically positioned in regions where they contribute to overhead sign detection while minimizing impact on overall light distribution, thus reducing manufacturing complexity and cost while maintaining detection functionality.
Solution Approach 2:
The lens surface is segmented into different functional zones: areas with corrugated profiling for overhead sign detection and areas without corrugations for standard light distribution. This segmentation allows the optical system to perform multiple functions with different structural characteristics in different regions, avoiding the need for expensive uniform micro-optical elements across the entire surface.
2Ease of manufacture
If corrugated profiling is used to scatter light for overhead sign detection, then manufacturing costs are reduced, but the light distribution pattern may be affected
Solution Approach 1:
The corrugated profiling is applied locally in specific sub-areas of the lens rather than uniformly across the entire surface. This localized application ensures that the scattering effect is concentrated in regions where it contributes to overhead sign detection without significantly disrupting the overall light distribution pattern required for normal driving illumination.
Solution Approach 2:
The patent implements partial action by applying corrugations only in specific sub-areas rather than across the entire lens surface. This partial application is sufficient to achieve the overhead sign detection function while minimizing interference with the primary light distribution function, thus maintaining reliability of the light distribution pattern.
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 solution enables the detection of overhead traffic signs by scattering part of the light beam in a simple and cost-effective manner, reducing manufacturing costs and maintaining efficient light distribution patterns.
Implementation Method 1
Through the corrugated profiling, a scattering of part of the light beam emitted by the light source can be achieved in a simple way in terms of manufacturing
Data Source
AI summary
A headlamp for vehicles including a light source and an optical unit for generating a specified light distribution pattern that has a light-dark boundary. The optical unit has a lens with a light inlet-side surface and a light outlet-side surface. Tlight inlet-side surface and/or the light outlet-side surface has optical elements in a sub-area. Corrugated profiling is provided as the optical elements. This profiling has at least one arched projection that transitions at opposing edges of this section continuously into arched outlet sections and/or into a main surface of the light inlet-side surface or the light outlet-side surface.