Vehicle Headlight Lens with Press-Molded Light Tunnel Bends
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Solution Overview
Problem
Current vehicle headlight designs are inefficient in manufacturing costs and optical performance, particularly in imaging bright-dark boundaries for combined high-beam and low-beam functionality using traditional materials and processes.
Innovation Solution
The design incorporates a monolithic body of transparent material, specifically inorganic glass, with press-molded light tunnels and passage sections that form curved transitions to create bright-dark boundaries, allowing for efficient light guidance and imaging, with the second bend configured as a mirror image of the first, enabling cost-effective production and improved optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional materials and processes are used for headlight lens manufacturing, then manufacturing flexibility is maintained, but manufacturing costs are high and optical performance is insufficient
Solution Approach 1:
The patent changes the material parameter from traditional plastic to inorganic glass, enabling press-molding processes that simultaneously reduce manufacturing costs and improve optical performance. The glass material allows for precise formation of light tunnels and bends with better light guidance properties
Solution Approach 2:
The patent replaces traditional multi-step manufacturing processes with a press-molding process that forms the complete headlight lens including light tunnels and bends in a single step, eliminating subsequent treatment steps and reducing both cost and complexity
2Manufacturing precision
If complex post-treatment processes are applied to optically effective surfaces, then optical precision is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent performs the optical surface formation during the initial press-molding process, creating the optically effective surfaces with required precision before any other manufacturing steps. This preliminary action eliminates the need for subsequent treatment processes
Solution Approach 2:
The patent merges the formation of light tunnels, bends, and optically effective surfaces into a single press-molding operation, combining multiple manufacturing functions into one process step that produces the complete optical component
3Productivity
If traditional light guidance structures are used, then design simplicity is maintained, but light distribution efficiency and bright-dark boundary imaging are insufficient
Solution Approach 1:
The patent uses curved bend structures instead of straight light paths, forming smooth transitions that efficiently guide light around corners while maintaining total internal reflection. The curved geometry optimizes light distribution and creates the desired bright-dark boundary imaging
Solution Approach 2:
The patent divides the light guidance path into distinct segments: light entry faces, light tunnels with specific geometries, bends for directional changes, and light passage sections with optically effective exit faces. This segmentation allows optimized design of each function while maintaining overall efficiency
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 solution reduces manufacturing costs and enhances optical performance by achieving efficient light guidance and imaging, allowing for effective high-beam and low-beam functionality with improved light distribution and reduced need for post-treatment of the optically effective surfaces.
Implementation Method 1
light tunnel... via a first bend, forms transition into the light passage section for imaging the first bend as a bright-dark boundary
Implementation Method 2
body of transparent material including at least one light entry face and at least one optically effective light exit face
Data Source
AI summary
A vehicle headlamp comprising first second light sources and first and second lens. Each lens comprising a precision-molded, one-piece, element of a transparent material. Each one-piece element comprising a light tunnel and a light-conducting part having an optically effective light exit surface. The first lens light tunnel comprises an optically effective, light inlet surface and transitions into a light-conducting part while making a first bend for imaging the first bend as a light-shadow line by means of light coupled in or irradiated onto the light inlet surface. The second lens light tunnel comprises a second optically active, light inlet surface and transitions into a second light-conducting part while making a second bend for imaging the second bend by means of light coupled in or irradiated onto the light inlet surface, the second bend (substantially) being a variant of the first bend mirrored on a straight line.