Headlamp Projection Module Microstructure Illumination
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Solution Overview
Problem
Existing headlight projection modules struggle to illuminate non-circular light passage surfaces efficiently while maintaining homogeneous intensity distribution and high imaging quality.
Innovation Solution
Incorporating an optically effective microstructure with dimensions in the micrometer range, such as a wave or free-form structure, in the virtual object position of the secondary optics to refract and distribute light bundles across the largest possible area of the secondary optics, allowing for arbitrary shaping of the light passage surface and intensity distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a circular light passage surface is used in secondary optics, then imaging quality is maintained, but the area of the light passage surface is limited and cannot be optimized for specific lighting requirements
Solution Approach 1:
The patent applies asymmetry by transitioning from a conventional circular light passage surface to a non-circular shape (such as rectangular or polygonal). This asymmetric design allows the light passage surface area to be optimized for specific lighting requirements while maintaining compatibility with LED array configurations. The asymmetric shape enables better matching between the light source geometry and the optical path, thereby increasing the effective area without proportionally increasing system complexity.
Solution Approach 2:
The patent utilizes dimensionality change by modifying the geometric configuration of the light passage surface from a two-dimensional circular aperture to a non-circular shape that extends in specific directional dimensions. This allows optimization of the light passage surface area in directions that match the LED array layout, effectively utilizing space in a manner that circular designs cannot achieve, thereby increasing area efficiency without adding physical depth or volume.
2Productivity
If the light passage surface shape is changed to non-circular, then area efficiency and lighting performance are improved, but imaging quality may deteriorate
Solution Approach 1:
The patent applies local quality by optimizing specific regions of the optical system to compensate for the non-circular light passage surface. This includes designing asymmetric lens elements or adjusting the focal properties in different zones of the optical path to ensure that imaging quality is maintained despite the irregular geometry. By applying different optical characteristics to different local areas, the system achieves both high light transmission efficiency through the non-circular aperture and preserves imaging precision.
Solution Approach 2:
The patent utilizes parameter changes by adjusting key optical parameters such as focal length, curvature radii, and refractive indices of lens elements to accommodate the non-circular light passage surface. These parameter adjustments are specifically tailored to the geometric characteristics of the asymmetric aperture, allowing the optical system to maintain diffraction-limited imaging performance while maximizing light transmission through the optimized non-circular shape.
3Temperature
If LED light sources are used, then operating temperature is reduced and control flexibility is increased, but luminance value is lower compared to gas discharge lamps
Solution Approach 1:
The patent applies copying by using multiple LED light sources arranged in an array configuration that replicates the functional characteristics of a single high-luminance source. By distributing the luminance requirement across multiple LEDs working in parallel, the system achieves the necessary total illumination intensity while maintaining the low operating temperature and high control flexibility inherent to LED technology. Each LED operates within its optimal temperature range while collectively providing sufficient luminance.
Solution Approach 2:
The patent utilizes multi-functionality by designing the LED array and non-circular light passage surface to serve multiple functions simultaneously: generating adequate luminance through combined output of multiple LEDs, maintaining low operating temperatures through efficient heat distribution, enabling dynamic control flexibility through individual LED addressing, and optimizing light transmission through the asymmetric aperture. This multi-functional design allows a single system to achieve what would traditionally require multiple different light source types.
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
Enables efficient illumination of non-circular light passage surfaces with minimal loss of efficiency, achieving homogeneous illumination and improved customer acceptance without significant deterioration in imaging quality or light transmission efficiency.
Implementation Method 1
In a virtual object position of the secondary optics, i.e. in a light distribution generated by the primary optics, an optically effective, light-refracting microstructure is arranged in the beam path of the bundled light
Implementation Method 2
Each light guide has a light entry surface facing a light-emitting diode, a light exit surface directed in the light exit direction, and totally reflecting side surfaces formed between the light entry surface and the light exit surface
Data Source
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AI summary
The invention relates to a headlight projection module (10) for a motor vehicle for generating a predetermined light distribution. The projection module (10) comprises: a light source (11) for emitting light, a primary optic (12) for focusing at least a portion of the emitted light, and a secondary optic (14) for projecting at least a portion of the focused light into a light emission direction (3) of the projection module (10).In order to achieve the most efficient design of the projection module (10) and in particular to be able to illuminate non-circular secondary optics (14) as completely and homogeneously as possible, it is proposed that in a virtual object position of the secondary optics (14) an optically effective, light-refracting microstructure (24) is arranged in the beam path of the bundled light, wherein the microstructure (24) has dimensions of the function-determining structural elements (26, 27), in particular the height differences of the individual structural elements (26, 27), in the micrometer range.