Motor Vehicle Headlight Light Module Cylindrical Optic Height Reduction
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Solution Overview
Problem
Existing light modules for motor vehicle headlights face challenges in reducing the overall height and length while maintaining performance, particularly in generating strip-shaped secondary light distributions, due to limitations in primary optics and secondary optics design, which result in significant luminous flux losses and undesirable illuminance gradients.
Innovation Solution
Incorporating a cylindrical optic with minimal refractive power in horizontal sections and converging properties in vertical sections between the primary and secondary optics to reduce the vertical beam angle and enable anamorphic enlargement, thereby reducing the height of the secondary optics and overall light module length without substantial luminous flux losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional primary optics and secondary optics are used without cylindrical optics, then the light module can generate strip-shaped secondary light distributions, but the overall height and length of the light module become excessive
Solution Approach 1:
The patent introduces a cylindrical optic that operates in a different dimensional orientation - it has refractive power only in the vertical direction while being optically neutral in the horizontal direction. This anisotropic optical behavior allows independent control of vertical and horizontal beam parameters, enabling compact module dimensions without compromising optical efficiency
Solution Approach 2:
The optical system is segmented into distinct functional components: primary optics for horizontal beam shaping, cylindrical optics for vertical beam control, and secondary optics for final projection. This segmentation allows each component to be optimized independently, reducing the overall size while maintaining performance
2Length of stationary object
If deflecting mirrors or prisms are used to reduce the height of secondary optics, then the overall length of the light module can be reduced, but luminous flux losses occur
Solution Approach 1:
The cylindrical optic acts as an intermediary element between the primary and secondary optics. Instead of using mirrors or prisms that deflect light at angles causing losses, the cylindrical lens gently refracts light in the vertical direction while maintaining horizontal propagation, thereby reducing module length without significant luminous flux loss
Solution Approach 2:
The patent replaces the mechanical deflection system (mirrors or prisms) with an optical refraction system (cylindrical lens). This substitution eliminates the need for physical deflection that causes luminous flux losses, achieving compact dimensions through pure optical transformation
3Length of stationary object
If the secondary optics height is reduced significantly, then the light module becomes more compact, but sharp illuminance gradients and luminous flux losses occur
Solution Approach 1:
The cylindrical optic transforms the beam parameters anisotropically - compressing the vertical beam angle while maintaining horizontal spread. This parameter transformation allows the secondary optics to be shorter without creating sharp illuminance gradients, as the vertical compression is achieved through controlled refraction rather than abrupt deflection
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 configuration allows for the creation of light modules with secondary optics that are approximately two to five times lower in height, maintaining optical efficiency and reducing the overall length, while avoiding sharp illuminance gradients and luminous flux losses associated with deflection mirrors or prisms.
Implementation Method 1
a cylindrical optic with minimal refractive power in horizontal sections and converging properties in vertical sections between the primary and secondary optics
Implementation Method 2
converging properties in vertical sections between the primary and secondary optics to reduce the vertical beam angle and enable anamorphic enlargement
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A motor vehicle headlamp includes numerous semiconductor light sources disposed in a matrix, which can be activated individually for emitting light, numerous primary lenses disposed in a matrix, allocated to the semiconductor light sources, for bundling the light emitted by the semiconductor light sources and for generating a primary light distribution on light exit surfaces of the primary lenses, and a shared secondary lens for projecting the primary light distributions as secondary light distributions onto a roadway in front of the motor vehicle, such that the secondary light distributions illuminate a high-beam region. To reduce the structural height of the secondary lens without losses in terms of efficiency, the motor vehicle headlamp includes a cylindrical lens having a cylinder axis disposed in the beam path of the light module between the primary lenses and the secondary lens that is oriented such that it is substantially horizontal.