Automotive Headlamp Laser Module with Folded Optical Path
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Solution Overview
Problem
Existing headlamp systems struggle to meet regulatory requirements for illumination intensity and glare reduction while maintaining aesthetic appeal and cost efficiency, with many headlamps rated poorly in on-road illumination tests.
Innovation Solution
A compact low-beam kink module design utilizing a high luminance laser light source, elliptical reflector, and a folder with a bump to generate a kinked luminous intensity distribution, reducing packaging profile and enhancing lighting efficiency, which includes a projection lens of 10 mm height and an optical arrangement system with a single laser light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If lens height is reduced for aesthetic appeal and compact design, then packaging profile and vehicle integration are improved, but illumination intensity and regulatory compliance become difficult to achieve
Solution Approach 1:
The patent changes the fundamental parameter of light source luminance by using laser diodes with significantly higher luminance (cd/mm²) compared to conventional LEDs. This parameter change enables the optical system to achieve required illumination intensity with a reduced lens height of about 10 mm, resolving the contradiction between compact design and illumination performance
Solution Approach 2:
The patent introduces a folded optical path using a reflector and folder component, effectively adding a spatial dimension to the optical arrangement. This allows the light to traverse a longer optical path and achieve proper beam shaping within a compact vertical envelope, enabling intense illumination from a low-height lens
2Ease of manufacture
If conventional LED light sources are used, then cost and availability are improved, but illumination efficiency and regulatory compliance deteriorate
Solution Approach 1:
The patent changes the luminance parameter of the light source by adopting laser diodes, which provide substantially higher luminance output compared to conventional LEDs. This enables a single laser diode to replace multiple conventional LEDs, improving illumination efficiency while maintaining cost-effectiveness through reduced component count and assembly complexity
Solution Approach 2:
The patent merges the functions of multiple conventional LED sources into a single laser diode source. This consolidation achieves the same or better illumination efficiency with fewer components, simplifying the optical system while meeting regulatory requirements for headlamp performance
3Illumination intensity
If multiple light sources are used to meet illumination requirements, then illumination coverage is improved, but device complexity and packaging size increase
Solution Approach 1:
The patent combines the illumination function of multiple conventional LED sources into a single laser diode source. This single source provides sufficient illumination coverage and intensity, reducing the number of components needed while meeting regulatory requirements. The optical system uses a reflector and folder to distribute the light from this single source across the required coverage area
Solution Approach 2:
The single laser diode source performs multiple functions that would traditionally require separate light sources: it provides both the intense central beam and the distributed illumination coverage through the optical arrangement. The reflector and folder components enable this single source to achieve multi-directional light distribution, reducing overall device complexity
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 achieves enhanced illumination efficiency, reduced packaging, and compliance with regulatory standards, providing improved on-road illumination and aesthetic appeal by generating a kinked beam pattern that meets various international lighting regulations.
Implementation Method 1
a high luminous source to emit light along an optical axis... where the high luminous source may include a laser light source
Implementation Method 2
a reflector for reflecting the light emitted from the high luminous source forward; wherein the reflector has a reflection surface represented by an elliptical surface
Implementation Method 3
a projection lens having a height of about 10 mm that is arranged in operative relationship with the reflector
Implementation Method 4
a folder arranged in an optical path between the reflector and the projection lens, where the folder includes a bump to generate the first luminous intensity distribution with the kink or elbow
Data Source
AI summary
The present invention relates to an optical arrangement system for an automotive headlamp that includes a first low-beam module adapted to generate a first luminous intensity distribution with a kink or elbow feature where the low-beam module includes: a high luminous source to emit light along an optical axis; a reflector for reflecting the light emitted from the at least one high luminous source forward; a projection lens having a height of about 10 mm that is arranged in operative relationship with the reflector; a folder arranged in an optical path between the reflector and the projection lens where the folder includes a bump feature to facilitate the first luminous intensity distribution generation with application of the kink or elbow feature; and where the reflector has a reflection surface which features an elliptical surface whose center axis is not aligned with the optical axis.