Motor Vehicle Headlight Illumination Substrate Adhesive Mounting
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Solution Overview
Problem
Current motor vehicle headlight illumination devices require numerous components and complex assembly processes, leading to high costs and difficulties in automation due to the need for manual adjustment and alignment of multiple projection devices.
Innovation Solution
The use of a substrate layer with an edge section that is attached to the support frame via adhesive, allowing for alignment and adjustment of micro-optics arrays before curing the adhesive, reducing installation space and enabling automated manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple projection devices are mounted and adjusted using three-point attachments and adjustment screws, then alignment precision can be achieved, but device complexity and assembly time increase significantly
Solution Approach 1:
The patent merges the substrate layer with the support frame by directly attaching the substrate to the support frame, eliminating the need for separate three-point attachments and adjustment screws. This integration reduces the number of components and simplifies the assembly process while maintaining alignment precision through the rigid connection between the substrate and support frame.
Solution Approach 2:
The patent extracts and eliminates the adjustment screws and three-point attachment mechanism from the assembly. By removing these complex adjustment components, the design achieves simpler assembly while relying on the precise positioning capabilities of the substrate layer itself and the adhesive bonding process to maintain alignment.
2Manufacturing precision
If multiple individual components are used for mounting and adjusting projection devices, then alignment can be achieved, but the number of components and assembly costs increase
Solution Approach 1:
The substrate layer serves multiple functions simultaneously: it supports the micro-optics array, provides structural rigidity, enables precise positioning, and acts as the mounting surface directly attached to the support frame. This multi-functionality eliminates the need for separate mounting brackets, adjustment mechanisms, and alignment components.
Solution Approach 2:
The substrate layer is designed as a universal component that performs multiple roles: optical support, structural framework, positioning reference, and mounting surface. This multi-functional design reduces the total component count while maintaining all necessary alignment and mounting capabilities.
3Manufacturing precision
If traditional mounting methods with multiple components are used, then adjustment precision can be achieved, but installation space requirements increase
Solution Approach 1:
By integrating the mounting function directly into the substrate layer attachment to the support frame, the patent eliminates the need for additional mounting brackets and adjustment mechanisms that would occupy extra space. The direct attachment method achieves precise positioning within the available installation space without requiring additional clearance for mechanical adjustments.
4Manufacturing precision
If manual adjustment and alignment processes are used, then positioning accuracy can be achieved, but automation difficulty increases
Solution Approach 1:
The substrate layer is pre-positioned and pre-aligned with the support frame during the adhesive application process, before final curing. This preliminary positioning can be performed using automated vision systems or robotic positioning, eliminating the need for manual adjustment after assembly. The rigid substrate structure maintains this pre-established alignment throughout the curing process.
Solution Approach 2:
The patent replaces manual mechanical adjustment mechanisms with an automated adhesive bonding process. The positioning accuracy previously achieved through manual manipulation of adjustment screws is now achieved through automated adhesive application and curing, which can be fully integrated into automated manufacturing lines.
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 simplifies the assembly process, reduces installation space, and allows for automated manufacturing of motor vehicle headlights, improving efficiency and cost-effectiveness.
Implementation Method 1
the edge section is attached to the support frame at least in sections by means of an adhesive
Data Source
AI summary
The invention relates to an illumination device (10) for a motor vehicle headlight, which illumination device (10) has at least one projection device (100), which projection device (100) is arranged on a support frame (50) of the illumination device (10), wherein the at least one projection device (100) comprises the following:at least one micro-optics array (200), which has a plurality of micro-optics (210) arranged in a matrix-like manner in a plane orthogonal to a main emission direction (X) of the projection device (100),at least one substrate layer (300), on which the at least one micro-optics array (200) is arranged, wherein the at least one micro-optics array (200) is arranged on an optically active section (310) of the substrate layer (300), which optically active section (310) is at least partially light-permeable,at least one light source (400), which is designed to emit light beams, wherein the light beams are coupled into the optically active section (310) of the substrate layer (300) and coupled out through the at least one micro-optics array (200) in front of the illumination device (10) as light distribution, wherein the substrate layer (300) comprises an edge section (320) surrounding the optically active section (310) and projecting in a partially planar extension of the optically active section (310), wherein the edge section (320) is attached to the support frame (50) at least in sections by means of an adhesive (500).