Light Module Screen Layout for Stray Ray Blocking
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Solution Overview
Problem
Existing light modules for automotive applications require precise positioning of components, leading to increased weight and complexity in production, and result in undesirable stray light rays due to the absence of a screen to intercept direct light rays.
Innovation Solution
A light module design featuring a screen positioned close to the light source with a convex end face and specific geometric configurations to intercept direct light rays, allowing for precise positioning and reducing module height, while using a thin projection lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a screen is added to block direct light rays, then stray light is reduced, but device complexity increases
Solution Approach 1:
The screen is integrated with the platform structure, merging two functions (support and stray light blocking) into a single component. This reduces device complexity while maintaining the stray light blocking function.
Solution Approach 2:
The platform serves dual purposes: supporting the light source and housing the screen that blocks direct light rays. This multi-functionality approach reduces the number of separate components needed in the module.
2Weight of moving object
If the projection lens is made thin, then weight is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The design accepts thin lens parameters to reduce weight, and compensates for the increased manufacturing difficulty through precise positioning mechanisms and optimized optical paths that are more tolerant of minor variations.
3Manufacturing precision
If component positioning precision is increased, then optical performance is improved, but ease of manufacture decreases
Solution Approach 1:
The screen and light source are pre-positioned relative to each other on the platform during manufacturing, establishing precise geometric relationships before final assembly. This preliminary positioning ensures optical performance while simplifying the final assembly process.
Solution Approach 2:
The screen is nested within the platform structure, with the light source positioned between them. This nested arrangement naturally constrains component positions and maintains precise spacing without requiring complex adjustment mechanisms during assembly.
4Length of moving object
If module height is reduced, then packaging space is improved, but device complexity increases
Solution Approach 1:
The screen extends in the transverse direction rather than requiring additional vertical space. By utilizing the transverse dimension for stray light blocking, the design achieves compact height while maintaining functionality through a different spatial arrangement.
Solution Approach 2:
The screen has an asymmetric geometry with a convex end face that is optimized for blocking direct light rays while minimizing vertical profile. The asymmetric shape allows efficient stray light rejection in a compact form factor.
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 effectively blocks direct light rays, reduces module height, and simplifies production by enabling easier assembly and weight reduction, while maintaining optical efficiency.
Implementation Method 1
a collector (8) with a reflective surface (8.2) configured to collect and reflect the light rays into a light beam reflected along an optical axis (10)
Implementation Method 2
an optical system configured to project the reflected light beam by imaging a part of the reflective surface
Implementation Method 3
a screen (14) positioned in front of the light source (4)... configured to collect light rays coming directly from the source
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a light module (2) comprising a light source (4) capable of emitting light rays; a plate (6) bearing the light source (4); a collector (8) with a reflective surface (8.2) configured to collect and reflect the light rays into a reflected light beam along an optical axis (10); an optical system (12) configured to project the reflected light beam by imaging a portion of the reflective surface (8.2); a screen (14) located in front of the light source (4), in a main direction of propagation of the reflected light beam, and configured to collect light rays coming directly from the source, which rays are referred to as direct rays (16); wherein the screen (14) extends in a transverse direction (14.1) with a constant cross-section and is arranged on the plate (6).