Vehicle Headlight Inner Lens Merging Collimation and Reflection
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Solution Overview
Problem
Existing light modules for vehicle headlights face challenges in reducing size while maintaining the required spread and illuminance in the left-right direction for low beams, particularly in achieving sufficient illuminance, especially in the center region under a cutoff line.
Innovation Solution
The use of an inner lens with collimating and reflecting functions instead of a reflector for low beams, combined with an outer lens having a convex emission surface, allows for reduced module size while ensuring wide light distribution and higher illuminance in the center region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a reflector is used for low beam, then the light distribution can be controlled, but the size of the light module increases
Solution Approach 1:
The patent combines the collimating function and reflecting function into a single inner lens component. The inner lens includes a light-receiving surface with collimating function and a reflector surface with reflecting function, merging what would traditionally be separate optical components into one integrated element, thereby reducing overall module size while maintaining low beam performance
Solution Approach 2:
The inner lens serves multiple functions simultaneously: it receives light from the light source, collimates the light in the front-rear direction, reflects light in the left-right direction, and guides light forward. This multi-functional design replaces what would traditionally require multiple separate components, achieving size reduction while preserving illuminance and light distribution
2Volume of stationary object
If the size of the reflector is reduced, then the light module size decreases, but the illuminance of the low beam becomes insufficient
Solution Approach 1:
By merging the collimating and reflecting functions into the inner lens, the patent eliminates the need for a large separate reflector. The integrated design maintains sufficient illuminance through optimized optical paths within the compact inner lens structure
Solution Approach 2:
The patent changes the optical parameters by using refraction at the light-receiving surface for collimation and reflection at the reflector surface for lateral light guidance. This parameter change allows the system to achieve the same illuminance effect with a more compact configuration
3Illumination intensity
If the light distribution region is maintained wide in the left-right direction, then the spread requirement is met, but the size of the light module increases
Solution Approach 1:
The inner lens is designed with different functional zones: the light-receiving surface handles collimation in the front-rear direction, while the reflector surface handles light distribution in the left-right direction. This local differentiation of optical functions allows compact sizing while maintaining wide lateral spread
Solution Approach 2:
The patent uses the three-dimensional structure of the inner lens to achieve light distribution in multiple directions simultaneously. The reflector surface is positioned and shaped to redirect light laterally, while the overall lens structure maintains forward collimation, effectively using spatial arrangement to achieve wide spread without increasing module footprint
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 maintains the necessary light distribution and illuminance in the left-right direction, achieving a more compact design by substituting the reflector with the inner lens and utilizing the outer lens to diffuse light effectively.
Implementation Method 1
a light-receiving surface having a function (a collimating function) for receiving light from the light source (a light emitting diode) and condensing or collimating a part of the light
Implementation Method 2
a reflector surface having a function (a reflecting function) for receiving and reflecting a part of the light received by the light-receiving surface and guiding the part of the light in a forward direction
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A light emitting diode for low beam of a light module for a headlight of a vehicle emits light in a forward direction. When viewed in a horizontal cross-section through a light emitting surface of the light emitting diode for low beam, a light-receiving surface of an inner lens for low beam includes a convex bottom surface section and a circumferential surface section. A reflector surface is located on the right of the light-receiving surface and reflects the first light received by the light-receiving surface. An emission surface is located in front of the convex bottom surface section and the reflector surface and emits the first light received by the light-receiving surface. A light guide section guides the first light received by the light-receiving surface to a first emission surface. An outer lens includes an emission surface. The emission surface is curved in a convex shape, receives the light emitted from the emission surface, and emits light for low beam.