Lens Holding Device Spring Locking Thermal Expansion
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Solution Overview
Problem
Existing lens systems for motor vehicle headlights face issues with lenses becoming loose at elevated temperatures due to thermal expansion, leading to variations in optical quality and requiring complex and costly manufacturing solutions.
Innovation Solution
A lens system with a holding device that includes a contact area and a locking element with a spring element, which secures the lens in place by exerting a spring force opposite to the main emission direction, preventing movement and maintaining optical alignment even at elevated temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a threaded ring is used to fasten lenses in the holding device, then the lenses are securely mounted, but the manufacturing becomes complex and costly
Solution Approach 1:
The patent extracts the lens fastening function from a separate threaded ring component and integrates it directly into the holding device structure. The holding device now includes integrated fastening elements that directly secure the lens, eliminating the need for additional threaded ring components and simplifying both manufacturing and assembly processes while maintaining secure lens mounting.
Solution Approach 2:
The patent merges the lens holding function and the fastening function into a single integrated holding device structure. The fastening elements are incorporated directly into the holding device rather than being separate components, combining multiple functions into one component to reduce overall device complexity and manufacturing cost.
2Reliability
If a threaded ring is used to fasten lenses, then the lenses are securely mounted, but the assembly process becomes error-prone and difficult to automate
Solution Approach 1:
The patent removes the complex threaded ring fastening mechanism and replaces it with simplified integrated fastening elements in the holding device. This extraction of the problematic component enables automated assembly systems to easily secure lenses without the errors associated with threaded ring installation, improving both reliability and automatability.
Solution Approach 2:
The patent changes the fastening mechanism from a threaded connection (requiring precise rotational alignment and torque control) to a simplified integrated fastening system with different geometric parameters. This parameter change makes the assembly process more tolerant of variations and easier to control in automated manufacturing environments.
3Ease of manufacture
If lenses are mounted in the holding device, then optical functions are formed, but thermal expansion causes lenses to become loose at elevated temperatures
Solution Approach 1:
The patent incorporates elastic elements into the integrated holding device that provide dynamic adjustment capability. These elastic elements allow the holding device to adapt to thermal expansion of the lens by flexing or deforming elastically, maintaining secure contact and preventing the lens from becoming loose at elevated temperatures while keeping the manufacturing process simple.
Solution Approach 2:
The patent changes the mechanical properties of the holding device by incorporating elastic materials or elastic elements that can change their dimensional parameters in response to temperature changes. This parameter change allows the holding device to compensate for thermal expansion of the lens, maintaining reliable mounting across temperature variations without complex manufacturing.
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 lens system ensures secure and reliable mounting of lenses at elevated temperatures, maintaining consistent optical quality and allowing for the generation of reliable lighting functions, such as dynamic floor projections, without the need for complex manufacturing or error-prone assembly processes.
Implementation Method 1
the locking element has a spring element which is designed to, in the fastened state of the locking element to the end section, on the at least one lens, in particular on a section of the light exit surface of the at least one lens, to engage and exert a spring force on the at least one lens
Implementation Method 2
the holding section has a contact area which is designed to block a, in particular coaxial linear, movement of the at least one lens against the main radiation direction beyond the initial section of the holding device
Data Source
Figure 1a~2b
Figure 3~5d
AI summary
Lens system (1) which can interact with a lighting means (2), comprising a holding device (3) with a contact region (8), a starting section (3a), an end section (3c) and a holding section (3b) for holding the at least one lens (4), wherein a locking element (5) is provided which can be fastened to the end section (3c) of the holding device (3), wherein the locking element (5) has a spring element (6), wherein in the fastened state the at least one lens (4) is fixed by the contact region (8) and the spring element (6), or the starting section (3a) has a spring element (6') and the locking element (5) has a contact region (8'), wherein in the fastened state the at least one lens (4) is fixed by the contact region (8') and the spring element (6').