Vehicle Headlamp Lens Segmentation for Continuous Light Patterns
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Solution Overview
Problem
The existing vehicle light assemblies produce non-continuous light patterns due to the reliance on flank surfaces for light reflection, resulting in unsatisfactory visual effects and limited design variability.
Innovation Solution
A vehicle light assembly with a light emitter module featuring a curved light exit surface, parabolic reflection surfaces, and adjustable flank surfaces that allow for independent control of light distribution, enabling uniform and continuous illumination without relying on flank surfaces for light reflection, thus allowing for design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If flank surfaces are used for light reflection to control light distribution, then light pattern control is achieved, but design variability of flank surfaces is limited and non-continuous light patterns with dark regions occur
Solution Approach 1:
The lens is divided into functionally independent regions: reflection surfaces for light control and flank surfaces for design aesthetics. This segmentation allows each region to be optimized independently - the reflection surfaces ensure continuous light patterns while the flank surfaces provide design variability without interfering with light distribution.
Solution Approach 2:
The light reflection function is extracted from the flank surfaces and assigned to dedicated reflection surfaces. This extraction frees the flank surfaces from their light control function, allowing them to be designed with various profiles and curvatures for aesthetic purposes while the reflection surfaces maintain continuous light patterns.
2Ease of operation
If multiple reflections between flank surfaces are used to transmit light, then light distribution is controlled, but the light pattern is significantly affected by flank surface geometry limiting design options
Solution Approach 1:
The lens is divided into functionally independent parts: reflection surfaces handle light distribution control while flank surfaces provide design flexibility. This functional segmentation resolves the contradiction by allowing each component to be optimized for its specific purpose without compromising the other.
Solution Approach 2:
The reflection surfaces act as intermediaries between the light emitter and the external environment, taking over the light control function from the flank surfaces. This intermediary role allows the flank surfaces to be designed freely for aesthetic purposes while the reflection surfaces ensure proper light distribution.
3Manufacturing precision
If flank surfaces are optimized for light reflection, then light pattern control is improved, but design varieties of the lens cannot be increased
Solution Approach 1:
By segmenting the lens into reflection surfaces and flank surfaces with distinct functions, the invention allows precision optimization of the reflection surfaces for light patterns while simultaneously enabling design variety in the flank surfaces, resolving the trade-off between precision and versatility.
Solution Approach 2:
Different regions of the lens are assigned different qualities and functions: the reflection surfaces have precise geometric properties optimized for light control, while the flank surfaces have varied profiles and curvatures optimized for aesthetics. This local differentiation allows both precision light patterns and design variety to coexist.
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 provides a vehicle light assembly with improved illumination efficiency and brightness, eliminating dark regions in the light distribution pattern and allowing for various design configurations of the flank surfaces without affecting the light pattern, meeting regulatory requirements.
Implementation Method 1
the light assembly includes left and right reflection surfaces (43) respectively connected to left and right sides of the light entry surface (41) to reflect light rays of the light emitter (5) incident on the light entry surface (41) toward the curved light exit surface (42)
Implementation Method 2
a curved light exit surface (42) disposed at a front side of the lens (4)... to reflect light rays of the light emitter (5) incident on the light entry surface (41) toward the curved light exit surface (42)
Data Source
Figure 1
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AI summary
A lens (4) of a vehicle light assembly includes a front curved light exit surface (42), a rear light entry surface (41) spaced apart from the curved light exit surface (42) along an optical axis and convexed rearwardly (L), left and right reflection surfaces (43) connected to the light entry surface (41), and left and right flank surfaces (45) connected to the left and right reflection surfaces (43) and to the curved light exit surface (42). A minimum distance (d1) of each flank surface (45) from the optical axis (L) is greater than a maximum distance (d2) of each reflection surface (43) from the optical axis (L).