Automotive Headlight Secondary Optical System Upper Zone Illumination
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Solution Overview
Problem
Existing automotive headlight systems face challenges in providing adequate illumination in the upper zone of the high beam without increasing the size of the headlight assembly, as the addition of a dedicated optical module for this purpose is not easily feasible due to the precise volume calculations of projector components.
Innovation Solution
A secondary optical system is integrated within the existing projector module, utilizing secondary LEDs that emit light outside the main light source's path, with a common exit lens and a diffusing/reflecting element to generate a supplementary beam that enhances upper zone illumination without disturbing the main optical elements, thus maintaining the initial module's volume and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a dedicated optical module is added to provide illumination in the upper zone of the high beam, then the illumination intensity in the upper zone is improved, but the volume and complexity of the headlight assembly increase
Solution Approach 1:
The patent combines the main optical system and secondary optical system within a single headlight assembly, sharing common structural elements and space. The secondary optical system is integrated into the existing projector module rather than being added as a separate dedicated module, thereby providing upper zone illumination while avoiding significant volume increase.
Solution Approach 2:
The headlight assembly is designed to perform multiple functions: the main optical system provides the primary high beam, while the secondary optical system provides supplementary illumination in the upper zone. Both systems operate within the same assembly, making the headlight multi-functional without requiring separate dedicated modules for each function.
2Illumination intensity
If a dedicated optical module is added to provide illumination in the upper zone of the high beam, then the illumination intensity in the upper zone is improved, but the device complexity increases
Solution Approach 1:
The patent merges the secondary optical system with the existing main optical system, sharing common structural support, housing, and spatial arrangement. This integration approach provides the necessary upper zone illumination while minimizing the increase in overall device complexity by reusing existing structural elements.
Solution Approach 2:
The secondary optical system is nested within the volume and structure of the main optical assembly. The secondary system is positioned and configured to fit within the existing projector module's spatial envelope, allowing both systems to coexist without substantially increasing the overall device complexity.
3Reliability
If secondary LEDs are positioned to emit light outside the main light source's path, then the two beams do not interfere with each other, but the space arrangement becomes more complex
Solution Approach 1:
The patent positions the secondary LEDs at specific locations (above and/or to the side of the main light source) with specific emission directions oriented toward the common exit lens. This localized positioning strategy ensures that secondary light rays travel through different portions of the optical system than the main beam, guaranteeing beam independence while maintaining a relatively simple spatial arrangement.
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 allows for simultaneous or alternate emission of two beams that do not substantially interfere with each other, providing improved driver visibility by adding diffuse, wide-spread light in the upper part of the photometric grid, enhancing viewing comfort without increasing the headlight's size.
Implementation Method 1
the light source being formed by at least one light-emitting diode
Implementation Method 2
a projection optical system, in the form of a lens
Implementation Method 3
a diffusing/reflecting element to generate a supplementary beam
Implementation Method 4
a diffusing/reflecting element to generate a supplementary beam
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The module has main optical elements provided with a main LED (LP) and a projection optical system in a form of a lens (L) or a paraboloidal type reflector, and secondary optical elements provided with a secondary LED (LS1) associated with a collimator (C1) and with a folding mirror (M). The main and secondary elements respectively emit main i.e. motorway type beam, and secondary light beams. The mirror deflects the light emitted by secondary LED, by using the collimator, in a direction of the optical system, and avoids interception of light emitted by the main LED.