Integrated Low-Beam Condenser for Cut-Off and Luminance Control
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Solution Overview
Problem
Existing vehicle light modules with condensers are complex in structure, large in size, and costly due to the use of multiple LEDs and light shields to control luminance, failing to meet regulatory requirements efficiently.
Innovation Solution
A condenser for low-beam vehicle light modules integrating light condensing structures, cut-off line forming, and luminance reducing structures, including a 50L dark area forming structure, zone III forming structure, and SEG10 luminance reducing structure, which refract and reflect light to achieve the desired low-beam light shape without the need for additional light shields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple LEDs and light shields are used to control luminance and form cut-off lines, then regulatory requirements are met, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple optical functions (light condensing, cut-off line formation, and luminance reduction) into a single integrated condenser component. This merging eliminates the need for separate light shields and multiple LEDs, reducing structural complexity while maintaining compliance with regulatory requirements for low-beam light shapes.
Solution Approach 2:
The condenser is designed as a multi-functional optical element that simultaneously performs light condensing, forms cut-off lines, and reduces luminance in specific zones. This universal design allows one component to replace multiple specialized parts, simplifying the overall vehicle light module structure.
2Reliability
If tens of LED light sources are used to control luminance zones, then regulatory light shape requirements are achieved, but manufacturing cost increases
Solution Approach 1:
The patent integrates multiple optical functions into a single condenser component, eliminating the need for numerous individual LED light sources. This consolidation significantly reduces the number of components that need to be manufactured, assembled, and controlled, thereby lowering manufacturing costs while maintaining regulatory compliance.
Solution Approach 2:
The patent extracts and consolidates the luminance control function into the condenser's optical design rather than using multiple LEDs. By taking out the need for numerous controllable LED elements and incorporating the control function directly into the condenser's structure, manufacturing complexity and cost are reduced.
3Manufacturing precision
If multiple light condensing structures are used, then light distribution control is improved, but module size increases
Solution Approach 1:
The patent merges multiple light condensing structures into a single integrated condenser with complex internal optical surfaces. This unified structure achieves precise light distribution control through its designed optical geometry rather than through multiple separate condensing elements, thereby maintaining precision while reducing module size.
Solution Approach 2:
The patent transitions from using multiple discrete light condensing structures arranged in space to a single condenser with complex three-dimensional optical surfaces. This dimensional approach allows precise light control to be achieved through the condenser's internal geometry rather than through the arrangement of multiple external components.
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 condenser achieves high light source efficiency, reduces module size, eliminates the need for fans, enhances heat dissipation, and ensures compliance with regulatory luminance standards while minimizing costs.
Implementation Method 1
the light condensing structures 1 comprise a front center inlet structure 1-1, a lateral center inlet structure 1-2 and a reflecting structure 1-3
Implementation Method 2
the reflecting structure 1-3 is located at the tail end of the condenser and disposed on the outer side of the light condensing structure 1 and is conical
Implementation Method 3
the cut-off line forming structure 2 has an end, with an arc-shaped end face contour curve, close to the lens and is disposed at a front end of the condenser
Implementation Method 4
the SEG10 luminance reducing structure (5) is a protrusion with a sloped section and is disposed at the bottom of the condenser, wherein light shining on the SEG10 luminance reducing structure (5) is reflected and refracted so as to reduce the luminance of an SEG10 test zone
Implementation Method 5
light shining on the SEG10 luminance reducing structure (5) is reflected and refracted so as to reduce the luminance of an SEG10 test zone of the low-beam light shape
Implementation Method 6
a 50L dark area forming structure 3, wherein the 50L dark area forming structure 3 is disposed at the bottom of the condenser perpendicular to the light spreading direction
Implementation Method 7
light shining on the 50L dark area forming structure 3 is weakened after being reflected and refracted by the 50L dark area forming structure 3
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
A condenser for a low-beam vehicle light module comprises light condensing structures (1), a cut-off line forming structure (2), a 50L dark area forming structure (3), a zone III forming structure (4) and an SEG10 luminance reducing structure (5). The zone III forming structure (4) comprises a zone III breadth forming structure (4-1) and an HV luminance reducing structure (4-2). The cut-off line forming structure (2) is disposed at a front end of the condenser. The SEG10 luminance reducing structure (5) is disposed at the bottom of the condenser. The zone III forming structure (4) is disposed at the bottom of the condenser and is located at a front end of the SEG10 luminance reducing structure (5). The 50L dark area forming structure (3) is disposed at the bottom of the condenser and is located between the zone III forming structure (4) and the cut-off line forming structure (2). The condenser of the invention integrates all optical elements other than the lens with all condenser parts, thereby improving space utilization efficiency, ensuring positional accuracy between optical functional components, eliminating positioning errors, and having a low cost.