Automotive Headlamp Reflector Design for Uniform High Beam
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Solution Overview
Problem
Existing motor vehicle headlamp lighting modules face challenges in producing a high beam without a dark band between cut-off beams, often requiring complex mechanisms and reducing the maximum intensity of the driving beam.
Innovation Solution
A lighting module that creates a cut-off beam without horizontal or vertical masks, using a reflector design where the images of the emitter meet a control curve entirely on the light spot's side, allowing for improved sharpness and maximum intensity, and can be combined with another reflector to produce a dual-function module with a main beam without a dark band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bender and lens are used to create cutoff beams for dual-function modules, then the module can generate both low beam and high beam, but a dark band appears between the superimposed beams and the maximum intensity of the high beam is reduced
Solution Approach 1:
The patent removes the bender component entirely from the optical system. Instead of using a bender to create cutoff beams, the invention uses a reflector with a specifically designed geometry that directly generates the cutoff beam pattern. This extraction of the problematic bender element eliminates the dark band issue while maintaining dual-function capability through the reflector's inherent optical design
Solution Approach 2:
The patent inverts the traditional approach by placing the light source at the focal point of a reflector rather than using a bender-lens system. The reflector is designed with a specific curvature and orientation so that light rays reflecting off it naturally form the cutoff beam pattern without requiring additional optical elements. This inversion of the optical path eliminates the dark band problem
2Adaptability or versatility
If a bender is used for upper cutoff of low beam and lower cutoff of supplementary beam, then dual-function is achieved, but the design becomes more complex and requires additional mechanisms
Solution Approach 1:
The reflector is designed to perform multiple functions simultaneously: it generates the low beam cutoff pattern, creates the supplementary beam cutoff, and enables high beam formation when combined with another reflector. This multi-functional reflector design eliminates the need for separate bender components and their associated control mechanisms, significantly reducing device complexity while maintaining dual-function capability
Solution Approach 2:
The patent merges the functions of the bender and lens into a single integrated reflector structure. The reflector's geometry is specifically designed to combine the cutoff beam generation and beam shaping functions that were previously separated into multiple components. This merging reduces the number of parts and eliminates the need for complex mechanisms to switch between beam modes
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 enables a simpler design with improved beam sharpness and intensity, eliminating the need for complex mechanisms and achieving a uniform high beam without dark bands, enhancing the overall lighting performance.
Implementation Method 1
a first reflector (R1) associated with said first emitter (1) and determined so as to create a light spot (S) in the plane of said first emitter (1)
Data Source
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AI summary
Lighting module comprising: - a plane light emitter (1), - a reflector (R1) determined so as to create in a plane including the emitter (1), a light spot (S) limited by a control curve (A) contained in the plane including the first emitter and constituting the front or rear edge of the spot; - a lens (L) determined and arranged with the reflector so as to form the first cutoff beam.