Vehicle Headlamp Module With Vertical Beam Widening
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Solution Overview
Problem
Existing headlight technologies face challenges in achieving high headlight resolution while maintaining a large projection area, particularly in high-definition (HD) functionality, often leading to restricted overall projection areas.
Innovation Solution
A headlight module with an LED pixel array and a freeform lens that allows for independent control of LED pixels, combined with an optical element designed as a freeform lens, which selectively widens the projection area vertically without affecting horizontal resolution, enabling both high beam and HD functionality in a single module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the illumination area per pixel is reduced to increase headlight resolution, then the resolution is improved, but the overall projection area is restricted
Solution Approach 1:
The headlight optical system is divided into multiple independent optical zones, each with its own projection lens and LED pixel array. The first optical zone is dedicated to high beam with a first projection lens, while the second optical zone handles low beam with a second projection lens. This segmentation allows each zone to be optimized independently for its specific function, enabling high resolution in the high beam zone without compromising the overall projection area through the addition of the second zone
Solution Approach 2:
The patent introduces a vertical dimension to the optical system by stacking multiple optical zones at different heights. The first optical zone for high beam is positioned at a first height, while the second optical zone for low beam is positioned at a second height. This vertical arrangement allows the high beam to achieve high resolution through reduced illumination area per pixel, while the low beam zone compensates for the restricted horizontal projection area by providing additional illumination coverage from its elevated position
2Adaptability or versatility
If a multi-focal-length lens is used to switch between high beam and low beam modes, then beam mode switching is achieved, but the device complexity increases
Solution Approach 1:
Instead of using a single complex multi-focal-length lens that switches between modes, the patent segments the lighting function into separate optical zones with dedicated projection lenses. Each lens is optimized for its specific beam type (high beam or low beam), eliminating the need for complex focal length switching mechanisms while maintaining the ability to provide both beam modes simultaneously or independently
Solution Approach 2:
The headlight module achieves multi-functionality by integrating multiple optical zones within a single housing. The first optical zone provides high beam illumination, the second optical zone provides low beam illumination, and both can operate simultaneously. This universal design allows the headlight to adapt to different driving conditions without requiring complex switching mechanisms, as both beam types are always available from their respective zones
3Area of stationary object
If the projection area is extended in the vertical direction using a freeform lens, then the high beam projection area is enlarged, but the horizontal resolution may be affected
Solution Approach 1:
The freeform projection lens is designed with spatially varying optical properties, where different regions of the lens have different focal lengths and refraction characteristics. The lens is configured to extend the projection area primarily in the vertical direction while maintaining appropriate horizontal resolution through localized optical adjustments. This local quality variation allows the lens to achieve asymmetric projection area expansion without uniformly compromising horizontal resolution across the entire beam
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 achieves an enlarged high beam projection area with maintained high resolution in critical areas, ensuring a smooth transition between high and low beam projection areas without dark zones, supporting both HD functionality and glare-free high beam operation.
Implementation Method 1
The optical element is configured to shape the respective LED light into a partial light beam for illuminating a partial area of the high beam projection area and/or the low beam projection area
Implementation Method 2
an LED pixel array with a number of LED pixels, each emitting a single LED light source
Data Source
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AI summary
The invention relates to a headlamp module (1) of a vehicle headlamp for generating a headlamp light having a first projection region (20) and a second projection region (30). The headlamp module (1) comprises an LED module (6) having a number of LEDs for emitting in each case an LED light and having a headlamp optics (7) for shaping the respective LED light to in each case a partial light beam for illuminating in each case a partial region of the first projection region (20) and/or the second projection region (30). The headlamp optics (7) is designed such that the first projection region (20) can be illuminated by a first group of partial light beams and the second projection region (30) by a second group of partial light beams, wherein the headlamp optics (7) comprises an optical element (9) for selectively widening the projection regions of the partial light beams, so that the projection regions of the first group of partial light beams can be widened in at least one direction.