Automobile Lamp Pattern Module with Lenticular Lens Array
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Solution Overview
Problem
Automobile lamp surface light sources have low optical efficiency and high manufacturing costs, failing to effectively achieve a three-dimensional effect.
Innovation Solution
A pattern module for automobile lamps comprising a substrate, a reflective sheet, an optical sheet with a lenticular lens, and a light source, where the optical sheet is manufactured using a process involving exposure solutions, ultraviolet treatment, and nickel plating to create a lenticular lens array, enhancing light guidance and three-dimensional pattern implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a surface light source is used to improve the design, then the three-dimensional effect is enhanced, but the optical efficiency becomes low and manufacturing cost increases
Solution Approach 1:
The optical sheet is segmented into multiple functional layers including a reflective sheet with regular reflection properties, an optical sheet with lenticular lenses, and an optical synthetic resin layer. This segmentation allows each layer to perform its specific function efficiently, maintaining optical efficiency while achieving the three-dimensional effect through coordinated action of all layers
Solution Approach 2:
The reflective sheet acts as an intermediary between the light source and the optical sheet. It performs regular reflection to direct light efficiently into the lenticular lenses, which then create the three-dimensional effect. This intermediary structure resolves the contradiction by separating the light direction function from the three-dimensional effect generation function
2Shape
If a surface light source is used to improve the design, then the three-dimensional effect is enhanced, but the manufacturing cost becomes high
Solution Approach 1:
The lenticular lenses on the optical sheet create multiple virtual images of the light source by refracting light at different angles. This optical copying effect produces the three-dimensional effect without requiring physically complex three-dimensional structures, thereby reducing manufacturing cost while maintaining the desired visual effect
Solution Approach 2:
The optical sheet structure serves multiple functions simultaneously: the reflective sheet directs light, the lenticular lenses create three-dimensional effects, and the optical synthetic resin protects and integrates the structure. This multi-functionality reduces the need for additional separate components, simplifying manufacturing and reducing costs
3Device complexity
If conventional lighting components are used, then the structure is simple, but the optical efficiency is low
Solution Approach 1:
Multiple optical functions are merged into a single integrated optical sheet structure. The reflective sheet, lenticular lenses, and optical synthetic resin are combined in one assembly that works together to achieve high optical efficiency. This merging maintains relative structural simplicity while dramatically improving optical performance compared to conventional separate components
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 solution enables the creation of various lamp light patterns with a three-dimensional effect, improving optical efficiency and reducing manufacturing costs by implementing a 3D stereoscopic image with linear, angled, and curved patterns.
Implementation Method 1
a reflective sheet which is provided on the substrate and performs regular reflection
Implementation Method 2
an optical sheet provided on the reflective sheet; an optical synthetic resin which is provided on the optical sheet and guides the light
Implementation Method 3
a third step of disposing the mask above the specimen on which the exposure solution is applied and then exposing the mask to ultraviolet ray to etch a portion excluding the mask to form an uneven pattern on a surface of the specimen
Implementation Method 4
a fourth step of manufacturing a pattern having a shape of the lenticular lens having an uneven pattern by applying heat on the specimen on which the uneven pattern is formed through the third step
Implementation Method 5
a light source which is provided on the substrate
Data Source
AI summary
An exemplary embodiment of the present invention provides a pattern module for an automobile lamp including: a substrate; a reflective sheet which is provided on the substrate and performs regular reflection; an optical sheet provided on the reflective sheet; an optical synthetic resin which is provided on the optical sheet and guides the light; and a light source which is provided on the substrate.