Vehicular LED Module Lens with Canted Input Surface
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Solution Overview
Problem
Conventional vehicle headlamps suffer from low light transmission efficiency, typically below 50%, and dimensional constraints that hinder both aesthetic and aerodynamic integration, particularly when curved or oriented in a vehicle-rearward fashion, leading to inefficiencies in light distribution and increased energy usage.
Innovation Solution
The use of a vehicle headlamp module with a lens featuring a plurality of near-field lens elements, a canted input surface, and an exit surface, along with an LED light source, which directs incident light through the input and exit surfaces to achieve a collimated light pattern that transmits at least 60% of the incident light, enhancing both light transmission efficiency and design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional headlamp assemblies are integrated into curved or aerodynamic vehicle designs, then aesthetic and aerodynamic performance is improved, but light transmission efficiency deteriorates
Solution Approach 1:
The lens is divided into multiple optical zones with different refractive indices and curvature radii. Each zone is optimized for specific light transmission requirements, allowing the lens to maintain high light transmission efficiency while accommodating curved or aerodynamic vehicle designs. The segmentation enables different regions of the lens to perform different optical functions simultaneously.
Solution Approach 2:
Different regions of the lens are assigned different optical properties, including varying refractive indices, curvature radii, and thicknesses. This local differentiation allows the lens to optimize light transmission in specific areas while maintaining the desired aesthetic and aerodynamic characteristics of the headlamp assembly in curved or aerodynamic vehicle designs.
2Ease of operation
If conventional headlamps use multiple components (light source, collector, light distributor), then light distribution control is improved, but device complexity and dimensional constraints increase
Solution Approach 1:
The patent combines the light source, light collector, and light distributor functions into a single integrated lens assembly. The lens itself performs multiple functions: collecting light from the source, distributing it in the required pattern, and shaping it to achieve the desired optical output. This merging eliminates the need for separate components while maintaining light distribution control.
Solution Approach 2:
The lens is designed as a multi-functional component that simultaneously serves as the light collector, light distributor, and optical shaper. By embedding multiple functions within a single element, the patent reduces overall device complexity while preserving the ability to control light distribution effectively.
3Volume of moving object
If conventional headlamps are designed with low profile, then packaging efficiency is improved, but light transmission efficiency deteriorates
Solution Approach 1:
The patent addresses the profile height constraint by optimizing the lens geometry in multiple dimensions simultaneously. The lens incorporates complex curvature patterns and refractive index variations that allow efficient light transmission even when the overall headlamp profile is compressed to a low profile. By utilizing three-dimensional optical design, the patent achieves both compact packaging and high light transmission efficiency.
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 configuration significantly improves light transmission efficiency, allowing for more compact and efficient headlamp designs that maintain high light output without substantial losses, even when integrated into curved or aerodynamic vehicle designs.
Implementation Method 1
a lens having a plurality of near-field lens elements, a canted input surface, an exit surface and a cavity between the surfaces. The headlamp module also includes an LED lighting module that directs incident light through the input and exit surfaces. The lens elements are configured to transmit from the exit surface a collimated light pattern containing at least 60% of the incident light.
Data Source
AI summary
A vehicular LED assembly is provided that includes a plurality of vehicular LED modules, each comprising: a lens with a canted input surface and an exit surface; a bezel surrounding the lens; and an LED light source positioned to direct incident light through the input surface. The input surface comprises a plurality of near-field lens elements for shaping the incident light into a collimated light pattern emanating from the exit surface. Further, the plurality of optical elements may be configured in a step-wise pattern defined by a sweep angle.