Projector Headlight Optical Units for Clear Cutoff Lines
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Solution Overview
Problem
Conventional vehicle headlights using LED optical units face challenges in forming favorable light distribution patterns, particularly in creating clear cutoff lines and elbow lines for low beams, while maintaining a simple structure and avoiding increased power consumption and complexity in the driver circuit.
Innovation Solution
A projector headlight design utilizing multiple optical units with specific optical axes and projector lenses featuring total reflection and reflex surfaces, allowing for adjustable curvature factors and angles to create overlapping light distribution patterns that include elbow lines, thereby achieving a favorable light distribution with high visual quality and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple optical units are used to form favorable light distribution patterns, then the light distribution quality is improved, but the device complexity increases
Solution Approach 1:
The headlight system is divided into multiple optical units (first, second, third optical units) with different optical axes and light distribution patterns. Each unit is responsible for specific regions of the light distribution, with the first optical unit providing a narrow pattern, the second providing a wider pattern, and the third providing the widest pattern. This segmentation allows complex light distribution to be achieved through coordinated simple units.
Solution Approach 2:
Each optical unit is designed with specific local characteristics - different optical axis orientations and different light distribution pattern widths. The first optical unit has its optical axis parallel to the vehicle's central line, the second intersects at a first angle, and the third intersects at a second angle. Each unit creates a light distribution pattern with specific angular characteristics, allowing precise control of light distribution in different spatial regions.
2Stability of the object's composition
If the number of optical units is increased to prevent brightness variability, then the light distribution uniformity is improved, but the device complexity and power consumption increase
Solution Approach 1:
The patent uses three optical units with progressively wider light distribution patterns rather than using many units with identical patterns. The second optical unit's wider pattern partially covers the first unit's distribution area, and the third unit's even wider pattern covers both previous units' areas. This overlapping partial coverage approach ensures brightness uniformity without requiring an excessive number of optical units.
3Adaptability or versatility
If optical units are arranged on a circular arc to emit light along curved roads, then the adaptability to driving conditions is improved, but the space requirement and alignment complexity increase
Solution Approach 1:
The optical units are arranged asymmetrically with respect to the vehicle's central line. The first optical unit's optical axis is parallel to the central line, while the second and third units have optical axes that intersect the central line at different angles. This asymmetric arrangement allows the light distribution to be optimized for typical driving conditions including curved roads, while maintaining a compact and simple overall structure.
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 design enables the formation of clear cutoff lines and wide light distribution patterns with high brightness and reduced glare, enhancing the visual quality and design flexibility of vehicle headlights while maintaining a simple driver circuit and efficient power usage.
Implementation Method 1
a projector lens (7) having a cavity that is located toward the reflex surface (13a)
Data Source
AI summary
The disclosed subject matter includes a projector headlight using a plurality of optical units for a low beam with a high visible/visual quality. Each of the optical units can include a plurality of LED devices and a projector lens. The projector lens can include a light-emitting surface including a reflex function and a reflex surface including a light incoming surface that is located on the opposite side of the light-emitting surface. The LED devices can be located adjacent the light incoming surface, and the optical units can be located so that angles between optical axes of adjacent optical units can be identical. Thus, the projector headlight can form various favorable light distribution patterns by changing curvature factors of the light-emitting surface and the reflex surface of the projector lens in each of the optical units and by changing the angles between the optical axes of the adjacent optical units.