Motor Vehicle Headlight Light Module Alignment
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Solution Overview
Problem
Current motor vehicle headlight systems face inefficiencies in light coupling due to imprecise arrangement of light sources and primary optics, leading to suboptimal light projection and resolution, especially in adapting to varying traffic and lighting conditions.
Innovation Solution
A light module with a common circuit board and holder system, where spacer devices are used to align light sources and primary optics based on a transformation function, ensuring precise geometric transformation and optimal light coupling by defining reference planes and points, and adjusting the light and optics planes for maximum efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If light sources and primary optics are arranged using conventional mounting methods, then the headlight system is simple to manufacture, but the light coupling efficiency is suboptimal due to imprecise arrangement
Solution Approach 1:
The patent introduces a common holder as an intermediary component that mechanically connects both the circuit board (carrying light sources) and the primary optics. This holder serves as a mediator that enables precise relative positioning between light sources and primary optics through integrated mounting features, thereby improving light coupling efficiency without requiring extremely tight tolerances in separate manufacturing steps
Solution Approach 2:
The patent implements preliminary alignment features during the manufacturing process, such as pre-defined mounting positions and geometric transformations that are calculated and prepared in advance. This allows the light sources and primary optics to be precisely arranged relative to each other before final assembly, ensuring optimal light coupling while maintaining manufacturing feasibility
2Measurement precision
If the number of light sources is increased to improve light pattern resolution, then the resolution and detail capability increase, but the complexity of the headlight system increases
Solution Approach 1:
The common holder serves multiple functions simultaneously: it mechanically supports both light sources and primary optics, provides precise alignment references for both components, and enables thermal management for the light sources. This multi-functionality allows the system to handle a higher number of light sources without proportionally increasing overall system complexity
Solution Approach 2:
The patent segments the headlight system into modular components (circuit board with light sources, primary optics, and common holder) that can be independently manufactured and then precisely assembled. This segmentation allows for increased number of light sources in the light matrix while maintaining manageable system complexity through standardized interfaces and mounting mechanisms
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 approach enhances the optical efficiency of motor vehicle headlights by improving light coupling into primary optics, allowing for higher resolution and adaptability in light patterns, reducing reflection losses, and extending the service life of components through thermal and mechanical decoupling.
Implementation Method 1
each light source is configured to emit light from the respective light-emitting surface, and to incouple light into a respectively associated light-incoupling surface
Data Source
AI summary
The invention relates to a motor vehicle headlight (1) comprising a light module having a plurality of light sources (110, 120, 130) and a plurality of primary optics (210, 220, 230), wherein the light sources (110, 120, 130) each have a light-emitting surface (111, 121, 131) and are arranged on a common circuit board (50). The circuit board (50) has a circuit board reference point and a light reference plane, wherein the light reference plane is defined by at least three light reference points, and the circuit board reference point lies in the light reference plane. The primary optics (210, 220, 230) each have a light-incoupling surface (211, 221, 231) and a light-outcoupling surface (212, 222, 232), and are held in position by a common holder (60). The holder (60) has a holder reference point and an optics reference plane, which is defined by at least three optics reference points (21, 22, 23) and in which the holder reference point also lies. At least three spacer means (41, 42) are arranged between the circuit board (50) and the holder (60) at the respective light reference points and optics reference points.