Vehicle Headlamp Lens with Elliptical Reflecting Surface
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Solution Overview
Problem
Existing vehicle lighting tools face inefficiencies in light utilization due to reflection losses at metal reflective surfaces, leading to reduced light distribution effectiveness.
Innovation Solution
A lens body design where light within a specific angular range is refracted to enter at a critical angle, eliminating the need for metal deposition on the first reflecting surface, and incorporating a second reflecting surface to reverse the optical path and enhance light distribution patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal reflective film is formed on the lens body surface through metal deposition, then the reflecting surface can be created, but light loss occurs in the reflecting surface which decreases utilization efficiency of the light
Solution Approach 1:
The patent removes the metal reflective film from the optical path by using the inner surface of the lens body (which does not require metal deposition) as the reflecting surface. This extraction eliminates the light loss associated with metal deposition while maintaining the reflecting surface functionality.
Solution Approach 2:
The patent introduces the lens body's inner surface as an intermediary reflecting surface between the light source and the external environment. This intermediary surface provides reflection without requiring metal deposition, thus avoiding light loss while still creating the necessary reflecting surface.
2Loss of energy
If the optical axis of the light source is inclined with respect to the vertical axis, then light can enter the lens body at a critical angle or more for total internal reflection, but the incident angle must be precisely controlled
Solution Approach 1:
The patent employs a curved incident surface (spheroidal or aspherical) that is inclined relative to the optical axis. This curvature automatically ensures that light rays incident on the surface meet the critical angle requirement for total internal reflection, eliminating the need for precise angular control during manufacturing while maintaining high reflection efficiency.
Solution Approach 2:
The patent changes the geometric parameters of the incident surface by inclining it with respect to the optical axis and using a curved surface profile. This parameter change ensures that the incident angle of light rays meets the critical angle requirement for total internal reflection, reducing reflection loss without requiring precise angular control during assembly.
3Illumination intensity
If a second reflecting surface is added to reverse the optical path, then light distribution patterns can be enhanced, but the device complexity increases
Solution Approach 1:
The patent makes the lens body multi-functional by incorporating both the first and second reflecting surfaces within a single component. The lens body simultaneously performs refraction at the incident surface, reflection at the first inner surface, and reflection at the second inner surface, eliminating the need for separate reflector components and reducing overall device complexity.
Solution Approach 2:
The patent merges the functions of multiple optical components (incident surface, first reflecting surface, second reflecting surface) into a single lens body. This consolidation integrates the refraction and reflection functions that would otherwise require separate components, enhancing light distribution while reducing device complexity.
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 increases light utilization efficiency, reduces reflection losses, and allows for a more even light distribution, particularly in high beam and fog lamp applications, by ensuring regions far from the vehicle appear sufficiently bright while suppressing brightness near the vehicle.
Implementation Method 1
light within a predetermined angular range with respect to an optical axis of the light source is refracted in a concentrating direction to enter the lens body
Implementation Method 2
an incident angle of the light within the predetermined angular range with respect to the first reflecting surface may be a critical angle or more... since the light from the light source enters the first reflecting surface at the incident angle of the critical angle or more, a reduction in cost can be achieved without a need for metal deposition on the first reflecting surface, and reflection loss occurring in a vapor deposited surface can be reduced
Implementation Method 3
the second reflecting surface reflects light passing above the first focal point downward... When the light passing above the first focal point enters the light emitting surface without being reflected by the second reflecting surface, the light is emitted downward from the light emitting surface
Implementation Method 4
light from the light source enters into the lens body from an incidence part of the lens body, some of the light is reflected by a reflecting surface of the lens body, and then the light exits to the outside of the lens body through a light emitting surface of the lens body
Data Source
Figure 1~2
Figure 3A~3D
Figure 4
AI summary
A lens body is provided which is disposed in front of a light source and configured to emit light forward from the light source along a forward/rearward reference axis extending in a forward/rearward direction of a vehicle, the lens body including an incidence part; a first reflecting surface configured to totally reflect light entering from the incidence part; a second reflecting surface configured to totally reflect at least some of the light totally reflected by the first reflecting surface; and a light emitting surface, wherein the first reflecting surface includes an elliptical spherical shape rotatably symmetrical with respect to a major axis extending in the forward/rearward direction, in first and second focal points constituted by the elliptical shape of the first reflecting surface, the second focal point disposed at a rear side between the first and second focal points is disposed in the vicinity of the light source, the second reflecting surface extends rearward from a point spaced a predetermined distance from the first focal point in an upward direction, and, among the light totally reflected by the first reflecting surface, light reaching the light emitting surface without being reflected by the second reflecting surface and light reaching the light emitting surface after being totally reflected by the second reflecting surface are emitted from the light emitting surface to be radiated forward.