Motor Vehicle Headlamp Light Module Lens Design
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Solution Overview
Problem
Modern motor vehicle headlights using lightweight plastics face damage from high sunlight intensities, leading to the 'burning glass effect' that distorts light distributions and fails to meet legal requirements, as existing solutions like metal baffles or light diffusing elements either fail to achieve the required light-dark boundary or compromise aesthetic and optical quality.
Innovation Solution
A light module design where the second light-refracting surface is oriented relative to the object focal plane to enlarge the central light distribution horizontally without affecting the vertical image scale, using a plano- or biconvex lens with a second area having a different curvature than the first, to reduce the magnifying effect and prevent damage from sunlight, while maintaining compliance with legal illuminance standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a focusing lens is used to project the luminous image, then the light distribution is improved, but the burning glass effect causes damage to plastic components
Solution Approach 1:
The patent divides the lens into multiple segments or zones with different optical properties. Specifically, the lens comprises a first region with a first curvature radius and a second region with a second curvature radius, allowing different areas to handle light differently - some areas focus light while others scatter it to reduce the burning glass effect.
Solution Approach 2:
Different regions of the lens are assigned different local optical qualities. The first region has a specific curvature optimized for light focusing, while the second region has a different curvature optimized for reducing the burning glass effect. This local differentiation allows simultaneous achievement of good light distribution and reduced thermal damage risk.
2Object-affected harmful factors
If metal baffles are used to prevent the burning glass effect, then component damage is reduced, but the light-dark boundary becomes blurred
Solution Approach 1:
The patent replaces the mechanical baffle system with an optical solution - a specially designed lens with varying curvature radii. Instead of using metal baffles to block or scatter light physically, the lens itself optically manages the light distribution while simultaneously reducing the burning glass effect through its specific curvature design.
3Object-affected harmful factors
If light diffusing elements are introduced to counteract the burning glass effect, then component protection is improved, but the lens loses transparency and aesthetic quality
Solution Approach 1:
The patent changes the optical parameters of the lens by varying the curvature radius across different regions. Instead of introducing separate diffusing elements that would compromise transparency, the lens itself is designed with continuously varying curvature parameters, maintaining full transparency while achieving the desired light scattering effect to reduce the burning glass effect.
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 design achieves a more homogeneous light distribution that meets legal requirements by reducing the magnifying effect and minimizing damage from sunlight, ensuring the light module operates within safe thermal limits without compromising optical quality or aesthetic appeal.
Implementation Method 1
a focusing effect of the lens, which is set up to project the luminous image generated in the object space into the image space
Implementation Method 2
The risk of damage is greatest in one focal plane of the lens, as this is where the highest concentration of incident sunlight occurs
Implementation Method 3
the second area is designed in such a way that the focal surface is oriented relative to the object focal plane in such a way that a central area of a light distribution generated by the light module is enlarged only in the horizontal direction
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
Light module (100) for a motor vehicle headlight comprising at least one light source (21, 23), an object to be imaged (24, 25), wherein the at least one light source (21, 23) is configured to generate light with which the object to be imaged (24, 25) is illuminated, a lens (300, 301) having an optical axis (7) and two refractive surfaces (31, 320, 321), wherein a first refractive surface (31) faces the object to be imaged (24, 25) and the second refractive surface (320, 321) is opposite the first refractive surface (31) and has at least two differently shaped areas (33, 340, 341), wherein a first area (33) has an aspherical shape, is arranged centrally on the second refractive surface (320, 321), and illuminates the object to be imaged (24, 25) in is arranged in an object focal plane (351) of a first part (350) of the lens (300, 301),which first part (350) of the lens comprises the first region (33) of the second refractive surface (320, 321) and the first refractive surface (31), the image focal plane of the first part (350) of the lens (300, 301) being at infinity, wherein at least a second region (340, 341) of the second refractive surface (320, 321) has a free-form shape that deviates from the aspherical shape of the first region (33) and is designed such that a second part (360) of the lens (300, 301), which second part (360) comprises the second region (340, 341) of the second refractive surface (320, 321) and the first refractive surface (31), has an object-side focal surface (361) that deviates from the object focal plane (351).