Vehicular Headlamp Reflector Layout for Single-Substrate Beam Alignment
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Solution Overview
Problem
Vehicular headlamps with separate mounting substrates for low and high beam light sources increase the number of components, leading to complexity and inefficiency.
Innovation Solution
A vehicular headlamp design where both light sources are mounted on the same plane, using a single substrate with reflecting surfaces and a projection lens to direct light forward, reducing the number of components and optimizing light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate mounting substrates are used for the first light source and the second light source, then the light sources can be disposed on different planes, but the number of components increases
Solution Approach 1:
The patent merges the mounting functions for both the first light source and the second light source onto a single substrate. This single substrate includes a first mounting surface for the first light source and a second mounting surface for the second light source, eliminating the need for separate mounting substrates and reducing the total number of components while still allowing the light sources to be disposed on different planes through the substrate structure
2Illumination intensity
If multiple separate components are used for mounting light sources, then light distribution can be controlled, but the device size and complexity increase
Solution Approach 1:
The single substrate serves multiple functions simultaneously: it mounts both the first light source and the second light source, provides structural support, and enables light distribution control through its design features including the first and second mounting surfaces. This multi-functionality reduces device size by eliminating the need for separate mounting components while maintaining precise light distribution control
3Manufacturing precision
If separate mounting substrates are used, then each light source can be optimized independently, but the ease of manufacture decreases
Solution Approach 1:
The patent combines the mounting functions for both light sources into a single substrate with specifically designed first and second mounting surfaces. This integration maintains manufacturing precision by providing dedicated optimized surfaces for each light source while simplifying the assembly process, as both light sources are mounted on one substrate rather than requiring separate assembly operations for multiple substrates
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 design minimizes the number of components, enhances light distribution by overlapping low and high beam patterns, and reduces size and component complexity while maintaining precise light axis alignment.
Implementation Method 1
a first reflecting surface that is disposed in front of the first light source, and reflects the first light upward
Implementation Method 2
a second reflecting surface that is disposed above the second light source, and reflects, forward, the first light which reaches from the first light source via the first reflecting surface
Implementation Method 3
a third reflecting surface that is disposed above the second light source and below the second reflecting surface in a state of extending in a front-rear direction, is connected to the second reflecting surface at an edge portion so as to share the edge portion with the second reflecting surface, and reflects the second light from the second light source forward
Implementation Method 4
a projection lens that is disposed in front of the first reflecting surface, the second reflecting surface, and the third reflecting surface, and irradiates the first light and the second light forward
Data Source
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AI summary
A vehicular headlamp includes: a first light source that emits first light forward; a second light source that is disposed above the first light source and emits second light forward; a first reflecting surface that is disposed in front of the first light source, and reflects the first light upward; a second reflecting surface that is disposed above the second light source, and reflects, forward, the first light which reaches from the first light source via the first reflecting surface; a third reflecting surface that is disposed above the second light source and below the second reflecting surface, is connected to the second reflecting surface, and reflects the second light from the second light source forward; and a projection lens that is disposed in front of the first, second, and third reflecting surfaces, and the first and second light sources are disposed on the same plane.