Light Module With Integrated Secondary Optic for Headlight Distribution
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Solution Overview
Problem
Existing motor vehicle headlight light modules are complex and require significant manufacturing and adjustment effort to produce and align optical elements for optimal low-beam light distribution, limiting their compactness and simplicity.
Innovation Solution
A light module design featuring two semiconductor light sources with distinct focal areas and a one-piece refractive secondary optics, allowing for separate optimization and control of low-beam light paths to generate different distributions, such as city and highway lights, with reduced manufacturing precision and adjustment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate secondary optics are used for different low-beam paths, then each beam path can be independently optimized, but the device complexity and manufacturing precision requirements increase significantly
Solution Approach 1:
The patent merges multiple separate secondary optics into a single integrated secondary optic that serves multiple low-beam paths simultaneously. This single optic contains different subvolumes (first subvolume for first low-beam path, second subvolume for second low-beam path) that can be designed with different optical properties to optimize each beam path independently, while eliminating the complexity of assembling and aligning multiple separate components
Solution Approach 2:
The single secondary optic is segmented into different subvolumes, each optimized for specific beam paths. The first subvolume optimizes the first low-beam path while the second subvolume optimizes the second low-beam path, allowing independent optimization of each path within a unified component structure
2Adaptability or versatility
If multiple separate secondary optics are used for different low-beam paths, then beam path optimization is improved, but the adjustment effort and alignment precision requirements increase
Solution Approach 1:
By combining multiple secondary optics into one integrated component, the patent eliminates the need for separate assembly and alignment procedures for each optic. The single secondary optic is positioned as one unit relative to the aperture assembly and semiconductor light sources, significantly reducing adjustment effort and alignment precision requirements compared to coordinating multiple separate optics
Solution Approach 2:
The single secondary optic performs multiple functions by serving different low-beam paths simultaneously through its different subvolumes. This multi-functional design allows one component to replace what would traditionally require multiple specialized components, simplifying both manufacturing and assembly processes
3Device complexity
If a single secondary optic is used for multiple beam paths, then device complexity is reduced, but the manufacturing precision requirements for the single component increase
Solution Approach 1:
The single secondary optic is designed with segmented subvolumes, each responsible for optimizing specific beam paths. This internal segmentation allows each subvolume to be optimized independently for its specific function, distributing the precision requirements across different regions of the component rather than requiring uniform high precision throughout the entire optic
4Device complexity
If traditional single beam path design is used, then device simplicity is maintained, but the light distribution versatility and range are limited
Solution Approach 1:
The patent implements a dynamic optical system where different combinations of semiconductor light sources and corresponding beam paths can be activated to produce different light distributions. The system can switch between different low-beam paths (first low-beam path with first subvolume, second low-beam path with second subvolume) to adapt to different driving conditions such as city lighting or highway lighting, providing versatility while maintaining a relatively 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 generation of various light distributions with improved brightness and range, reducing component complexity and manufacturing tolerances, resulting in a more compact and efficient light module.
Implementation Method 1
a refractive secondary optic that collects light emanating from the focal areas of the first and second semiconductor light sources and directs it into a foreground of the light module
Implementation Method 2
a first primary optic that focuses light from the first semiconductor light source into a first focal area and a second primary optic that focuses light from the second semiconductor light source into a second focal area
Data Source
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AI summary
The invention relates to a light module (16) for a motor vehicle headlight (10), having a first semiconductor light source (18), a first primary optical unit (20), a second semiconductor light source (26), a second primary optical unit (28), a diaphragm (34, 68) and a secondary optical unit (36). The light module is characterised in that the secondary optical unit is designed as one piece and has a first partial volume (36.6) and a second partial volume (36.7), wherein light entering through a light input surface (36.3) of the first partial volume is focused more intensely in the horizontal direction than in the vertical direction, wherein light from the first semiconductor light source and the second semiconductor light source exiting a light output surface (36.1) of the secondary optical unit for both partial volumes is focused more intensely in the vertical direction than in the horizontal direction, and wherein the second partial volume (36.7) overall focuses the light of the second semiconductor light source more intensely in the horizontal direction than in the vertical direction.