Automotive Lighting Reflector Grain Pattern for Smooth Beam Cutoff
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Solution Overview
Problem
Existing automotive lighting modules produce lighting beams with undesirable irregularities, particularly sharp lower horizontal cutoffs and excessive downward extent, which can lead to luminous irregularities when multiple beams are superimposed.
Innovation Solution
Incorporating a grained front area on the reflective surface of the lighting module, truncating the reflective surface at its front end, and using a shield adjacent to the front edge to absorb and/or reflect light rays, thereby controlling the upper and downward luminous intensity and extent of the lighting beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the reflective surface is truncated at the front end to limit downward extent, then the downward luminous intensity is controlled, but a sharp lower horizontal cutoff is produced causing luminous irregularities
Solution Approach 1:
The reflective surface is divided into two distinct zones: a first grained area at the front end with high roughness (Ra ≥ 0.3 μm) to diffuse light and eliminate sharp cutoffs, and a second smooth area at the rear to maintain sharp upper cutoffs. This local differentiation of surface quality allows simultaneous control of downward luminous intensity and elimination of luminous irregularities.
2Manufacturing precision
If the reflective surface is made smooth to produce sharp cutoffs, then the upper cutoff is sharp, but the lower cutoff becomes sharp causing irregularities when multiple beams are superimposed
Solution Approach 1:
Different regions of the reflective surface are assigned different surface qualities: the first grained area (Ra ≥ 0.3 μm) creates a diffuse lower cutoff to prevent luminous irregularities, while the second smooth area maintains a sharp upper cutoff. This spatial differentiation of surface properties resolves the contradiction between cutoff sharpness and luminous regularity.
3Area of stationary object
If the reflective surface area is reduced to limit downward extent, then the lighting beam extent is controlled, but the luminous distribution becomes irregular
Solution Approach 1:
The reflective surface is functionally segmented into a front grained area (first area) and a rear smooth area (second area). The grained area's increased roughness diffuses light rays, creating a gradual lower cutoff that prevents luminous irregularities even when the overall surface area is reduced to control beam extent.
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 prevents undesirable luminous irregularities by ensuring controlled upper cutoffs and limited downward extent, aligning with regulatory luminous intensity limits, enhancing the overall lighting performance.
Implementation Method 1
the reflective surface comprises a front edge and a grained front area comprising the front edge... the grained front area has a roughness Ra greater than or equal to 0.3 μm
Implementation Method 2
the collector comprises a shield located directly in front of the front edge of the reflective surface, said shield being configured to absorb and/or reflect out of the optical device light rays passing in front of the front edge
Implementation Method 3
a collector with a reflective surface configured to reflect the light rays in a reflected beam
Data Source
AI summary
The invention relates to a lighting module for an automotive vehicle. The lighting module includes a light source adapted to emit light rays, a collector with a reflective surface configured to reflect the light rays in a reflected beam, an optical device configured to project the reflected beam in a projected beam along an optical axis of the lighting module by imaging a portion of the reflective surface. The reflective surface includes a front edge and a grained front area including the front edge.