Integrated Projection Headlight Optical Assembly

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Solution Overview

Problem

Existing projection headlights for vehicles face challenges with manufacturing and assembly tolerances due to separate primary optical systems, resulting in limited luminous flux utilization.

Innovation Solution

The design features parallel optical axes for the first and second light modules with separate primary and secondary optical systems, integrated shields, and modular components that can be manufactured as a single piece, reducing tolerances and enhancing luminous flux utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate primary optical systems are used for each light module, then each module can be independently optimized, but manufacturing and assembly tolerances must be compensated and luminous flux utilization is limited

Engineering Contradiction:

Improveindependent optimization of light modulesVSAvoidmanufacturing and assembly tolerances

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent combines the primary optical systems of multiple light modules into a single integrated optical system. This merging eliminates the interfaces between separate optical systems, thereby eliminating manufacturing and assembly tolerances that would otherwise need to be compensated. The unified optical system maintains the ability to optimize each light module independently while ensuring precise light distribution through a single molded structure.

Inventive Principle:

Principle #5Merging (Combining)

2Device complexity

If separate primary optical systems are used for each light module, then modular design is enabled, but assembly complexity and tolerance accumulation increase

Engineering Contradiction:

Improvemodular design capabilityVSAvoidassembly complexity

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent merges multiple separate primary optical systems into a single integrated optical component that can be manufactured as one piece. This eliminates the assembly steps required to combine separate optical systems, thereby reducing assembly complexity. The modular light modules can still be independently designed and optimized, but they are integrated into a unified optical structure that requires no assembly tolerance compensation.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If indirect light deflection by reflectors is used, then light can be redirected, but luminous flux utilization is limited

Engineering Contradiction:

Improvelight redirection capabilityVSAvoidluminous flux utilization

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent replaces mechanical light redirection systems (reflectors) with an integrated optical system that uses refractive elements and light guide structures. This substitution allows for more efficient light transmission and redirection, reducing energy loss. The integrated optical system can directly shape and direct light from multiple sources without the losses associated with multiple reflections, thereby improving luminous flux utilization while maintaining light redirection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 minimizes manufacturing and assembly tolerances, increases luminous flux usage, and reduces costs by allowing for single-piece manufacturing and alignment simplification, while maintaining high-intensity light distributions.

Implementation Method 1

a first light module (4) with a light source (9) and a primary optical system (P1, P2) for shaping the light emitted by the light source (9)

Methodology Applied

Scientific EffectLight emission: Light Emitting Diode

Implementation Method 2

a primary optical system (P1, P2) for shaping the light emitted by the light source (9)

Methodology Applied

Scientific EffectLight shaping: Refraction

Implementation Method 3

a secondary optical system (S1, S2) for projecting the light emerging from the primary optical system (P1, P2) of the first light module (4)

Methodology Applied

Scientific EffectLight projection: Lens

Implementation Method 4

a shield (15) with a shield edge (14) for producing a light/dark boundary (7, 8, 18) in the resultant light distribution

Methodology Applied

Scientific EffectLight blocking: Absorption (EM radiation)

Data Source

PatentUS11274802B2Projection headlight

Publication Date: 2022.03.15 HELLA GMBH & CO KGAA

AI summary

A projection headlight for vehicles having a first light module containing a light source and a primary optical system for shaping the light emitted by the light source, a second light module containing a light source and a primary optical system for shaping the light emitted by the light source, a secondary optical system, for projecting the light emerging from the primary optical system of the first light module in a region in front of the vehicle as a first light distribution and the light emerging from the primary optical system of the second light module as a second light distribution, a shield with a shield edge for producing a light/dark boundary in the resultant light distribution, wherein the primary optical systems of the first light module and of the second light module and the shield are connected to one another as a single piece.