Vehicle Headlight Heat Shield for Polymer Support Protection
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Solution Overview
Problem
Optical modules for automotive lighting, particularly elliptical types, face challenges with thermal degradation due to heat from light sources and solar radiation, especially when using plastic support parts, which are prone to damage from excessive temperature rises.
Innovation Solution
Incorporating a heat shield made of metallic material, such as sheet steel, between the polymer support parts and the converging lens or reflector, to block thermal radiation and prevent overheating, while maintaining the structural integrity and light beam properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If polymer support parts are used in optical modules, then weight is reduced and manufacturing complexity is decreased, but thermal degradation occurs due to heat from light sources and solar radiation
Solution Approach 1:
A heat shield made of metallic material is introduced as an intermediary component between the polymer support parts and the heat sources (light source and solar radiation). This heat shield blocks thermal radiation and prevents direct heat transfer to the polymer parts, thereby protecting them from thermal degradation while allowing the use of lightweight polymer materials
Solution Approach 2:
The invention converts the harmful thermal radiation from the light source and solar radiation into a manageable parameter by using the heat shield to redirect and block the heat. The heat shield itself becomes a beneficial element that protects the polymer parts, transforming the thermal challenge into an opportunity to use lightweight materials that would otherwise be unsuitable for high-temperature environments
2Reliability
If metal support parts are used instead of polymer parts, then thermal stability is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The support structure is segmented into two distinct parts: a polymer support part that provides the main structural framework and positioning functions, and a separate heat shield component that specifically addresses thermal protection. This segmentation allows each part to be optimized for its specific function - the polymer part for lightweight structural support and the metal heat shield for thermal management
Solution Approach 2:
The heat shield serves multiple functions: it blocks thermal radiation from the light source, reflects solar radiation, and provides a thermal barrier between external heat and the polymer support parts. This multi-functionality allows a single component to address multiple thermal challenges without requiring a complete metal construction
3Reliability
If metal support parts are used instead of polymer parts, then thermal stability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The support structure is divided into a polymer support part that can be manufactured using cost-effective injection molding techniques, and a separate heat shield that can be produced through stamping or extrusion. This segmentation allows each component to be manufactured using the most appropriate and cost-effective process for its material and function
Solution Approach 2:
The heat shield is designed as a simple, thin metallic component that can be easily manufactured and replaced if necessary. Its relatively simple construction and the use of standard metallic materials make it a cost-effective solution compared to using expensive high-temperature polymer materials or complex metal support structures
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 heat shield effectively protects polymer support parts from thermal degradation, allowing for widespread use of plastic components in optical modules, ensuring their longevity and performance without compromising the light beam characteristics.
Implementation Method 1
a heat shield (6), in particular made of metallic material, for example sheet steel, between at least a part of said part and the front of the module, characterized in that the heat shield (6) protects said part from overheating
Implementation Method 2
The heat shield effectively protects polymer support parts from thermal degradation, allowing for widespread use of plastic components in optical modules
Data Source
Figure 1
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Figure 3
AI summary
The module has a light source such as xenon lamp, placed in a reflector (2) for transmitting a light beam at the level of an output side of the reflector. A movable cover plate (8) is pivoted between two positions, and a motor (7) provokes the movement of the cover plate. A support part (4) is placed in front of the reflector, and a heat shield (6) is placed between the support part and the front of the module. The shield is fixed on the support part using locking pins. An independent claim is also included for a headlight equipped with an optical module.