Automotive Headlamp Light Module Using Segmented Catadioptric Optics
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Solution Overview
Problem
Existing motor vehicle headlight light modules are bulky and costly due to thick optics required for efficient light distribution, which complicates production and limits adaptability to non-circular light exit surfaces.
Innovation Solution
A light module utilizing an optical system of thin-walled astigmatic lenses with different focal lengths in vertical and horizontal planes, allowing for an anamorphic image and flexible light exit surface design without sacrificing efficiency, achieved through a catadioptric attachment optic with shared secondary optics and segmented primary optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If thick optics are used to achieve efficient light distribution, then optical efficiency is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The first optic is divided into multiple segments or facets, each directing light to different positions in the image plane. This segmentation allows the optic to be thinner while maintaining light distribution efficiency, as each segment independently directs light without requiring excessive thickness for total internal reflection across the entire surface.
Solution Approach 2:
The first optic features locally varied refractive indices or surface curvatures in different segments, enabling each region to optimally direct light to its designated area. This local optimization achieves efficient light distribution with reduced overall thickness compared to uniform thick optics.
2Illumination intensity
If the light-emitting surface is widened to increase light output, then illuminance is improved, but the center thickness of the second optical element must be increased
Solution Approach 1:
The patent transitions from a single thick optical element to a multi-element system where the first optic (with segments) and second optic (cylindrical lens) work in sequence. This dimensional restructuring allows light to be distributed across a wider area without proportionally increasing the center thickness of any single element, as the thickness is distributed across multiple thinner components.
3Use of energy by moving object
If thick optics with center thickness > 20 mm are used, then light distribution efficiency is improved, but manufacturing cycle time increases
Solution Approach 1:
By segmenting the first optic into multiple facets, the patent enables the use of thinner optical materials that can be manufactured more quickly via injection molding. The segmented design maintains light distribution efficiency through precise angular orientation of each segment, eliminating the need for long curing times associated with thick monolithic optics.
4Adaptability or versatility
If the light-emitting surface is made non-circular to match rectangular specifications, then adaptability is improved, but light efficiency decreases
Solution Approach 1:
The segmented first optic with its faceted structure enables independent control of light direction from each segment. This allows the optical system to efficiently direct light into rectangular or other non-circular patterns without wasting light, as each segment can be precisely oriented to direct light only where needed, maintaining high efficiency with adaptable output shapes.
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 results in a compact, cost-effective light module with high optical efficiency and illuminance, enabling adaptable light distributions and reduced manufacturing complexity.
Implementation Method 1
a catadioptric attachment optic (11) having a light entry surface and a light exit surface and having a first focal point behind the semiconductor light source
Implementation Method 2
The reflective surfaces of the optic 11 are segmented or faceted... a catadioptric transparent lens attachment
Implementation Method 3
a secondary optic for further focusing the light already focused by the primary optic and for generating a resulting light distribution on the roadway
Data Source
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AI summary
The invention relates to a light module (10) for a motor vehicle headlight (1), comprising: - a semiconductor light source (12) for emitting light, - a primary optic (11) for focusing the emitted light and having a focal point (17) which, viewed opposite a direction of light emission (3), is arranged behind the at least one semiconductor light source (12), - a secondary optic (15) for further focusing the light already focused by the primary optic (11) and for generating a resulting light distribution (30; 40; 60; 80) of the light module (10) on a roadway in front of the motor vehicle, wherein the secondary optic (15) has a focal point (18) or a focal line (18a) which, viewed opposite a direction of light emission (3), is arranged behind the at least one semiconductor light source (12), and wherein - the entire optical system of the light module (10) has a focal point (19) or a focal line (19a) whichwhich is located in the area of the light-emitting surface of the at least one semiconductor light source (12).