Integrated Light Guide and Optical Disc for Motor Vehicle Lamps
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Solution Overview
Problem
Current motor vehicle lights with separate light guides and optical discs require high manufacturing effort and cost due to the limited availability of injection molding machines, resulting in high production costs and limited optical quality, as well as the inability to fulfill multiple lighting functions effectively.
Innovation Solution
A motor vehicle lamp design featuring a component with spatially separated parts, one designed as a light guide and another as an optical disc, connected by a bridge, allowing for production using a single injection molding machine and enabling multiple lighting functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate light guides and optical discs are used in motor vehicle lights, then optical quality can be achieved, but manufacturing effort and production costs increase significantly
Solution Approach 1:
The patent combines the light guide and optical disc into a single integrated component that is molded in one injection molding process. This merging eliminates the need for separate manufacturing and assembly steps, reducing manufacturing effort while maintaining the optical quality that would otherwise require separate precision components.
Solution Approach 2:
The integrated component performs multiple functions simultaneously - it acts as both a light guide to direct light and an optical disc to create the desired light distribution pattern. This multi-functionality reduces the overall number of components needed in the lighting system.
2Adaptability or versatility
If multiple separate components are used in motor vehicle lights, then optical functions can be fulfilled, but production costs increase due to limited injection molding machine availability
Solution Approach 1:
By merging the light guide and optical disc into a single moldable component, the patent enables production using a single injection molding machine instead of requiring multiple machines for separate components. This reduces production costs by optimizing machine utilization while still achieving the necessary optical functions.
3Manufacturing precision
If separate light guide and optical disc components are used, then specific optical characteristics can be achieved, but assembly complexity and time increase
Solution Approach 1:
The integration of light guide and optical disc into a single component eliminates all assembly steps between these two parts. The component is installed as one unit, dramatically reducing assembly time while maintaining the precise optical characteristics that would require careful alignment of separate parts.
4Ease of manufacture
If conventional separate components are used in motor vehicle lights, then manufacturing processes are established, but the ability to fulfill multiple lighting functions is limited
Solution Approach 1:
The integrated component is designed to fulfill multiple lighting functions through its combined light guide and optical disc structure. The same component can support different light sources for various functions (headlights, fog lights, signal lights) while maintaining efficient light distribution, thereby increasing adaptability without requiring separate specialized components for each function.
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 design reduces production costs, simplifies assembly, and enhances optical quality by allowing a high-quality impression with fewer components, enabling the lamp to fulfill multiple lighting functions efficiently.
Implementation Method 1
A light guide (06), in particular a planar light guide, with a light decoupling surface (04) arranged on its front side, which is oriented, for example, normal to the main emission direction of a motor vehicle light
Implementation Method 2
at least one optical disc (07) with a corresponding light distribution pattern, which is designed, for example, by means of an at least partial coating or by means of a specific structure
Data Source
Figure 1
AI summary
A motor vehicle lamp is described, comprising a lamp interior enclosed by a lamp housing and a lens enclosing the housing. The lamp interior contains at least one light source with at least one light source to fulfill at least one lighting function of the motor vehicle lamp. Furthermore, the lamp interior contains at least one component (01) comprising at least a first section (02, 04) designed as at least one light guide (06) with corresponding light guide properties, and at least a second section (03, 05) designed as at least one optical lens (07) with corresponding optical lens properties.