Light Assembly with Opaque Cavity Separation and Multi-Polymer Lens
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Solution Overview
Problem
Conventional light assemblies for vehicles often have varying power requirements and light qualities across different lighting functions, which can lead to inefficiencies and unsatisfactory aesthetic and functional lighting effects, particularly in the integration of high-beam, low-beam, DRL, and position lighting functions.
Innovation Solution
A light assembly featuring a housing with an opaque portion separating two cavities, utilizing a transparent, homogenous multi-polymer illuminable outer lens made from a mixture of polycarbonate and polyetheresteramide, which allows for specific light transmittance and haze levels, and includes a controller to manage lighting functions, preventing light bleed between different lighting sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single housing contains multiple lighting functions (high-beam, low-beam, DRL, position lighting), then device integration is improved, but light quality control and aesthetic appearance deteriorate due to light bleed and inconsistent lighting effects
Solution Approach 1:
The housing is divided into separate cavities (first cavity for DRL/position lighting, second cavity for high-beam/low-beam) separated by an opaque portion. This segmentation prevents light from different sources from mixing, allowing each lighting function to maintain its specific light quality and aesthetic appearance while being integrated in a single housing structure.
Solution Approach 2:
An opaque portion (wall or baffle) is introduced as an intermediary element between the first and second cavities. This intermediary blocks light from the first cavity from entering the second cavity, preventing light bleed and ensuring that each lighting function operates with controlled light quality without interference from other sources.
2Ease of manufacture
If conventional materials are used for the outer lens, then manufacturing simplicity is maintained, but aesthetic appearance and light transmittance control deteriorate
Solution Approach 1:
The outer lens is constructed from a multi-polymer material combining polycarbonate and PEEA (polyetheresteramide). This composite material provides optimized optical properties including controlled light transmittance (at least 50%) and haze level (not more than 30%), while maintaining manufacturability through injection molding processes. The specific polymer combination achieves the desired balance between aesthetic appearance (clear when not active) and lighting performance.
3Illumination intensity
If light blocking structures are added to prevent light bleed, then light quality control is improved, but device complexity increases
Solution Approach 1:
The light blocking function is merged into the housing structure itself through the opaque portion that separates the cavities. Rather than adding separate light blocking components, the housing is designed with an integrated opaque wall or baffle that performs both structural support and light blocking functions, reducing overall device complexity while effectively preventing light bleed.
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 enables enhanced lighting effects by maintaining a clear appearance when not active and providing desired illumination when active, while optimizing packaging and weight by blocking unnecessary light scatter, thus improving the overall lighting functionality and aesthetic appeal.
Implementation Method 1
a light transmittance level of at least about 50% and a haze level of not more than about 30%
Implementation Method 2
haze level of not more than about 30%
Implementation Method 3
The opaque portion of the housing separates the first cavity from the second cavity and prevents an influx into the second cavity of light emitted by the first lighting source
Data Source
AI summary
A light assembly includes a housing defining separate first and second cavities, an illuminable outer lens constructed from a homogenous multi-polymer material, and a first lighting source within the first cavity. A second lighting source may be positioned in the second cavity. An opaque portion of the housing separates the first and second cavities and prevents an influx into the second cavity of light emitted by the first lighting source. The multi-polymer material, when irradiated by the first lighting source, illuminates with a light transmittance level of about 50% or more and a haze level of less than about 30%. A vehicle includes a body having a front end, a hood positioned at the front end, and the light assembly positioned adjacent to the hood. A controller may transmit a lighting control signal to the first lighting source to command a turn signal, daytime running light, park, or position function.