Vehicle Headlamp Lens Assembly With Spring Compensation for Thermal Expansion
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Solution Overview
Problem
Thermal expansion and subsequent cooling of lenses in vehicle headlamp systems cause loosening, leading to errors in ideal light distribution or light patterns.
Innovation Solution
A lens system with an array of lenses featuring an entrance lens, intermediate lenses, and an exit lens, where elastic distance means between lenses absorb thermal expansion forces, maintaining a stable configuration through sprung connections along the longitudinal axis of a lens holding member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lenses are arranged in a housing structure with spacers, then the lenses can be spaced apart and mounted individually, but thermal expansion causes loosening of lenses within the housing leading to errors in light distribution
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism that allows the lens positions to change automatically in response to thermal expansion. The adjustment mechanism includes threaded rods that can be rotated to move lenses along the optical axis, compensating for thermal effects and maintaining proper focus and light distribution patterns.
Solution Approach 2:
The patent employs adjustable parameters including the positioning of lenses along the optical axis through threaded mechanisms. This allows the system to adapt to thermal expansion by changing the distance between lenses and the light source, thereby maintaining optimal optical performance despite temperature variations.
2Reliability
If lenses are held rigidly in position, then light distribution remains stable, but thermal expansion forces cause loosening and movement of lenses
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism that allows the lens positions to change automatically in response to thermal expansion. The adjustment mechanism includes threaded rods that can be rotated to move lenses along the optical axis, compensating for thermal effects and maintaining proper focus and light distribution patterns.
Solution Approach 2:
The patent implements a feedback mechanism where the position of lenses is continuously monitored and adjusted based on thermal expansion effects. The adjustment mechanism responds to changes in lens position caused by thermal effects, automatically correcting the positioning to maintain stable light distribution.
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 system compensates for thermal expansion by absorbing forces with elastic distance means, resulting in a thermally stable lens system with consistent light distribution.
Implementation Method 1
the last distance means is elastic and arranged between the at least one intermediate lens and the exit lens and is configured to establish a sprung connection between the at least one intermediate lens and the exit lens
Implementation Method 2
The thermal expansion and a subsequent cooling (in case the light source is turned off) leads to a loosening of the lenses within the housing
Data Source
Figure 1
AI summary
Lens system (1) for a vehicle headlamp, wherein the lens system (1) comprises a light source (2), an array (3) of consecutively arranged lenses (3a, 3b, 3c), and a lens holding member (4), which is configured to encase the array (3) of lenses, wherein an entrance lens (3a), a first distance means (5a), at least one intermediate lens (3b), a last distance means (5b) and an exit lens (3c) are arranged consecutively within the lens holding member, wherein the last distance means (5b) enables a sprung connection between the exit lens (3c) and the at least one intermediate lens (3b) in such a way that a force, caused by a displacement of the entrance (3a) and/ or the intermediate lens (3b) along a longitudinal axis (x) due to thermal expansion, which acts towards the exit lens (3c) is absorbed by a compression of the last distance means (5b).