Headlamp Optical Element III-Region Light Shape Forming Structure
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Solution Overview
Problem
Existing vehicle lamp systems with LED light sources face challenges in compactness and efficiency due to the large size of reflecting and converging elements, leading to increased manufacturing costs and a mismatch with the trend towards more compact automobile designs.
Innovation Solution
A headlamp optical element with a light collecting portion, first and second light emitting portions, and a reflecting portion, where the light collecting portion converges incident light and emits it through the first light emitting portion, with some light directly emitted to the second portion and the rest reflected, forming a compact structure with a lower or high beam cut-off line, and integrated with a lens for improved optical efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a projection type lighting system with LED light source is used, then the vehicle lamp becomes more intelligent and the shape is more differentiated, but the size of the reflecting element needs to be large and the light converging element needs to be long, resulting in a large module size and increased manufacturing cost
Solution Approach 1:
The patent combines the light converging element and reflecting element into a single integrated optical element. The light converging element includes a light incident surface, a light emitting surface, and a reflecting surface that is integrally formed, eliminating the need for separate reflecting mirrors and reducing the overall module size while maintaining the required light distribution capabilities
Solution Approach 2:
The light converging element is designed to perform multiple functions simultaneously: it converges light from the LED source, reflects light to achieve the desired distribution pattern, and forms the illumination light shape with bright-dark cut-off line. This multi-functional design reduces the number of components needed in the system
2Reliability
If the light converging element is made long to guarantee lighting effect, then the lighting performance is improved, but the module size becomes large and more materials are used, increasing manufacturing cost
Solution Approach 1:
By integrating the reflecting surface into the light converging element, the patent achieves the required lighting effect with a more compact structure. The integral design allows light to be effectively utilized through the combining of convergence and reflection functions in a shorter optical path, reducing material consumption
3Area of stationary object
If the reflecting mirror or light converging element is made large, then the lighting coverage is improved, but the number of matched optical elements increases, further increasing manufacturing cost
Solution Approach 1:
The patent integrates multiple optical functions into a single light converging element that includes both light converging and reflecting surfaces. This reduces the total number of optical elements required in the system while maintaining the necessary light coverage area through the combined action of the integrated surfaces
Solution Approach 2:
The light converging element is designed as a multi-functional component that performs light convergence, reflection, and shape formation simultaneously. This universal design reduces system complexity by eliminating the need for multiple separate optical elements to achieve the same effects
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 results in a compact, high-efficiency vehicle lamp system that meets market requirements for miniaturization and diversification, reducing material usage and manufacturing costs while enhancing light distribution and precision.
Implementation Method 1
the light collecting portion is able to converge incident light and emit the light via the first light emitting portion
Implementation Method 2
the rest of the light being able to be reflected by the reflecting portion and then emitted to the second light emitting portion
Data Source
AI summary
A headlamp optical element with a III-region light shape forming structure that comprises a light collecting portion, a first light emitting portion, a reflecting portion, and optionally a second light emitting portion. The light collecting portion converges incident light and emits light via the first light emitting portion. Some light may be directly emitted to the second light emitting portion. The rest of the light may be reflected by the reflecting portion and emitted to the second light emitting portion. The reflecting portion is connected to the lower portion of the first light emitting portion, with a lower beam cut-off line structure at the other end thereof. The light emitting surface of the first light emitting portion comprises multiple step surfaces with segment differences or is a single curved surface.