Automotive Headlight Bender Reduces Upper Bulk
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Solution Overview
Problem
Existing motor vehicle headlamp lighting modules with cut-off beams face integration challenges due to large parabolic reflectors and the need for multiple light-emitting diodes, resulting in increased bulk and manufacturing complexity.
Innovation Solution
The lighting module design includes a bender that redirects light rays from an ellipsoidal reflector to a parabolic reflector, with the bender positioned to deviate reflected rays from the optical axis, allowing the second reflector to be located below the horizontal plane, and utilizing a folding mechanism to reduce transverse size and simplify manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a parabolic reflector is used to produce the cut-off beam, then the light beam quality is improved, but the bulk in the upper part increases
Solution Approach 1:
The patent relocates the parabolic reflector from the upper region to the lower region of the headlamp assembly, utilizing the lower dimension space that was previously underutilized. This spatial reconfiguration allows the reflector to maintain its optical function while reducing the bulk in the upper part where headlamp glass curvature constraints exist.
2Illumination intensity
If multiple light-emitting diodes are arranged in the same plane, then the luminous flux is improved, but the transverse dimension increases
Solution Approach 1:
The patent distributes multiple light-emitting diodes across different planes and vertical positions rather than arranging them all in the same plane. This three-dimensional arrangement allows the system to achieve high luminous flux while minimizing the transverse footprint, enabling better integration into vehicle bodywork.
3Adaptability or versatility
If the bender is positioned to redirect rays, then the integration into bodywork is improved, but the device complexity increases
Solution Approach 1:
The bender component is designed to perform multiple functions: it redirects light rays to achieve the desired beam pattern, defines the cut-off line through its edge positioning, and contributes to the overall structural integration into the headlamp assembly. This multi-functionality reduces the need for additional separate components.
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 achieves a cut-off beam with reduced upper bulk, easier integration into vehicle bodywork, and simplified manufacturing while maintaining high luminous flux and reduced transverse size, allowing for easier combination with other modules.
Implementation Method 1
a bender having a reflective surface... reflecting the rays coming from the first reflector which would intersect the optical axis of the second reflector on the side opposite the apex with respect to the focal point
Implementation Method 2
a first reflector, of the ellipsoidal type, having a first focus at which, or in the vicinity of which, the light source is arranged to illuminate towards the first reflector, and a second focus situated on the optical axis
Implementation Method 3
a second reflector, of the parabolic type, for producing the cut-off beam of the module forwards, the focal point of the second reflector being coincident with, or located in the vicinity of, second focal point of the first reflector
Data Source
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AI summary
The module has a bender (B) for passing light rays (row1), from a reflector (R1), and cutting an optical axis (A) between a focus (psi) and an apex (2) of another reflector (R2). The bender reflects light rays (row3), from the reflector (R1), cutting the optical axis of the reflector (R2) from a side opposite to the apex with respect to the focus, such that light rays (mu1, mu2) reflected toward the front are separated from the optical axis of the module. The reflector (R2) is located below a horizontal plane passing through the axis of the module when the module is placed in a motor vehicle.