Vehicle Headlamp Projection Module Mirror Placement
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Solution Overview
Problem
Existing motor vehicle headlights with multi-function projection modules face challenges in creating high beam distributions without light-dark boundaries, which can result in unwanted dark lines or crosstalk, and require additional components like mirrors that are aesthetically undesirable and limit design freedom.
Innovation Solution
The solution involves positioning a mirror in the second beam path between the beam waist and the projection lens to create a virtual mirror image of the beam waist, allowing for a high beam distribution that is free of light-dark boundaries, without the need for external mirrors or additional installation space, and using semiconductor light sources with independent beam paths for low and high beam functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mirror is arranged behind the projection lens to redirect high beam light, then high beam function is achieved, but the mirror becomes visible from outside creating an aesthetically undesirable appearance
Solution Approach 1:
The mirror is repositioned from the space behind the projection lens to the beam path between the beam waist and projection lens. This spatial reconfiguration moves the mirror into a different dimensional location within the optical path, allowing it to remain functional while becoming hidden from external view, thus resolving the aesthetic contradiction.
Solution Approach 2:
The mirror acts as an intermediary optical element that redirects light without being visible. By positioning it in the beam path between the beam waist and projection lens, the mirror mediates the light redirection function while its location within the optical assembly rather than behind the lens makes it invisible from outside, resolving the appearance issue.
2Ease of manufacture
If a mirror is placed behind the projection lens, then high beam distribution is achieved, but additional installation space is required limiting design freedom
Solution Approach 1:
The mirror is relocated from the z-dimension (behind the lens) to a position within the beam path between the beam waist and projection lens. This dimensional repositioning utilizes available space within the existing optical assembly footprint, eliminating the need for additional installation space behind the lens and reducing overall device complexity.
3Reliability
If multiple light sources with separate optics are used for low and high beam, then beam path separation is achieved, but device complexity increases
Solution Approach 1:
The projection lens serves multiple functions: it projects both low beam light distributions (when used with the diaphragm) and high beam light distributions (when used with the mirror). This multi-functionality allows a single optical component to handle both beam types, reducing the need for separate projection optics for each function and thereby reducing overall device complexity while maintaining reliable beam path separation through the mirror-diaphragm mechanism.
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
This configuration eliminates the appearance of dark lines between light distributions, reduces installation complexity, and enhances the efficiency of the projection module by allowing for a high beam distribution that is both aesthetically pleasing and compliant with lighting standards, while maintaining high illumination efficiency.
Implementation Method 1
a mirror (30), which is arranged in the second beam path (46) between the beam waist (44) and the projection lens (28) and which generates a virtual mirror image of the beam waist (44)
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a motor vehicle headlamp (10), comprising a multi-function projection module (14), which is designed to convert light from a first light source (16) into a first light distribution (34) by means of a first primary lens system (18) in a first beam path bounded by an aperture edge (26), and to focus light from a second light source (20) into a beam waist (44) and convert said light into a second light distribution by means of a second primary lens system (22) in a second beam path, the second light distribution having a predetermined central point (56). The projection module is characterized by a mirror (30), which is arranged in the second beam path between the beam waist (44) and the projection lens (28) in such a way that the mirror produces a virtual mirror image of the beam waist (44) at the focal point of the projection lens.