Vehicle Headlight Light Source Unit Cross-Shaped Reflector
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Solution Overview
Problem
Existing light source units for vehicle lamps face challenges in satisfying UN regulations for red light sources, particularly in achieving efficient light distribution and luminous flux percentages across defined areas, while also dealing with light attenuation and increased costs due to complex optical designs and high molding accuracy requirements.
Innovation Solution
A light source unit configuration featuring a cross-shaped reflector surrounding chip LEDs on a circuit board, with specific placement and connection of LEDs and reflective surfaces to optimize light distribution, minimize light attenuation, and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex optical designs with multiple reflectors and lenses are used to satisfy UN light distribution standards, then light distribution precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The reflector is divided into multiple reflective surfaces (first reflective surface and second reflective surface) with different inclination angles, where each surface is responsible for reflecting light from specific LED chips to designated areas. This segmentation allows independent optimization of each reflective surface to meet UN light distribution standards without requiring complex multi-component optical systems.
Solution Approach 2:
Different regions of the reflector are designed with locally optimized properties - the first reflective surface has a first inclination angle optimized for reflecting light to side areas, while the second reflective surface has a second inclination angle optimized for reflecting light to front areas. This local quality differentiation enables precise control of light distribution without increasing overall device complexity.
2Manufacturing precision
If high molding accuracy is required to achieve proper light distribution, then light distribution standards are satisfied, but manufacturing cost increases
Solution Approach 1:
The reflector is segmented into multiple surfaces with specific inclination angles that are easier to manufacture individually. The first reflective surface and second reflective surface can be produced using standard molding techniques with controlled precision, avoiding the need for extremely high molding accuracy across the entire complex optical system.
Solution Approach 2:
The reflector is designed as a disposable, low-cost component that can be manufactured using inexpensive injection molding techniques. By optimizing the reflector geometry with simple inclined surfaces rather than complex curved optics, the manufacturing cost is significantly reduced while still achieving compliance with UN light distribution standards.
3Volume of moving object
If LED chips are placed close to each other to reduce size, then compactness is improved, but light attenuation increases
Solution Approach 1:
The reflector is designed with spatially differentiated reflective surfaces positioned at different locations and orientations. The first reflective surface is positioned to receive light from specific LED chips and reflect it to side areas, while the second reflective surface is positioned to receive light from other LED chips and reflect it to front areas. This local quality differentiation allows close spacing of LED chips while maintaining adequate light output through optimized reflection paths.
Solution Approach 2:
The reflector acts as an intermediary between the closely spaced LED chips and the required light distribution pattern. By using the reflector's inclined surfaces to redirect light from the compact LED array to the appropriate areas, the system achieves both compactness and adequate light output without requiring large spacing between LED chips.
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 solution enhances light extraction efficiency while meeting UN light distribution standards, reduces costs by simplifying manufacturing, and ensures reliable performance under vehicle vibrations and impacts.
Implementation Method 1
a reflector 7 installed on the circuit board 6 to surround the four light emitting devices 5a to 5d, wherein the reflector 7 includes a first reflective surface 7a and a second reflective surface 7b
Data Source
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AI summary
A light source unit for a vehicle headlight includes a circuit board (6) on which four light emitting devices (5a to 5d) are disposed at each of four directions with respect to a center thereof, and a reflector (7) provided on the circuit board (6) so as to surround the four light emitting devices (5a to 5d), wherein the circuit board (6) includes four side areas (B1 to B4) in which the four light emitting devices (5a to 5d) are disposed, one center area (A) disposed at a center of the four side areas (B1 to B4) and four corner areas (C 1 to C4) disposed at corner sections next to the four side areas (B1 to B4), and the reflector (7) includes eight first reflective surfaces (7a) provided to divide spaces between each of the side areas (B1 to B4) and the corner areas (C1 to C4), and four second reflective surfaces (7b) provided to divide sides of each of side areas (B1 to B4) opposite to the center area (A).