Vehicle Headlight Beam Shaper Structure for Stable Low-Beam Cutoff
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Solution Overview
Problem
Existing vehicle headlights struggle to form precise low and high beam light distribution patterns without forming unintended dark or bright regions, and maintaining the shape of the cutoff line in the low beam pattern when the beam shaper is thinned.
Innovation Solution
A vehicle headlight design featuring a beam shaper with a plate-shaped main member and reinforcing member, where the main member includes a base portion with a fixed reinforcing member, and a position regulating portion to prevent deformation and misalignment, ensuring the formation of precise cutoff lines in the low beam pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional headlight assembly with separate reflector and lens components is used, then the headlight can provide illumination function, but the assembly becomes complex and difficult to manufacture
Solution Approach 1:
The patent merges the reflector and lens into a single integrated headlight assembly where the reflector is formed as an integral part of the lens structure. This eliminates the need for separate reflector and lens components, reducing assembly complexity and manufacturing difficulty while maintaining the headlight's illumination function.
Solution Approach 2:
The lens structure serves multiple functions simultaneously: it acts as both the lens for focusing light and the reflector for directing light. This multi-functional design reduces the number of components needed and simplifies the overall headlight assembly structure.
2Adaptability or versatility
If multiple separate components (reflector, lens, housing) are used in headlight assembly, then each component can be optimized independently, but the overall assembly becomes more complex and requires more installation steps
Solution Approach 1:
By combining the reflector and lens into a single integrated component, the patent reduces the number of parts that need to be installed. The integrated design maintains optimization capabilities while significantly simplifying the installation process, as fewer components need to be assembled and aligned.
3Ease of manufacture
If conventional headlight materials are used, then the headlight can be manufactured with standard processes, but the light transmission and reflection efficiency is insufficient
Solution Approach 1:
The patent employs a composite material structure where the lens is made from a material with specific optical properties that enable both efficient light transmission and integrated reflector functionality. This composite approach allows for optimized light efficiency while maintaining manufacturability through adapted standard processes.
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 design allows for the formation of accurate low and high beam light distribution patterns by preventing deformation and misalignment, thereby suppressing the formation of unintended dark or bright regions, and maintaining the shape of the cutoff line.
Implementation Method 1
an upper surface of the base portion reflects a part of the first light toward the projection lens in such a way as to form a cutoff line of the low beam light distribution pattern
Data Source
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AI summary
A vehicle headlight (1) includes: a first light emitting optical system (LE1) that emits first light (L1) from a first part; a second light emitting optical system (LE2) that emits second light (L2) from a second part positioned below the first part; a projection lens (35); and a beam shaper (50), in which the beam shaper (50) includes a plate-shaped main member (110) and a plate-shaped reinforcing member (120) overlapping the main member (110), the main member (110) includes a base portion (53) having a part that includes a front end of the main member (110) and does not overlap the reinforcing member (120) and a part that overlaps the reinforcing member (120) and to which the reinforcing member (120) is fixed, and an upper surface of the base portion (53) reflects a part of the first light (L1) toward the projection lens (35) in such a way as to form a cutoff line (CL) of a low beam light distribution pattern (PL).