Low-Beam Condenser Structure for Shield-Free Luminance Zoning
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Solution Overview
Problem
Existing vehicle light modules with condensers have low integration levels, require complex structures due to the use of light shields for forming cut-off lines and luminance control, leading to large sizes and high costs, and the need for numerous LEDs to adjust luminance.
Innovation Solution
A condenser for low-beam vehicle light modules integrating light condensing structures, cut-off line forming, 50L dark area forming, zone III forming, and SEG10 luminance reducing structures, using transparent plastic or resin materials to refract and reflect light for controlled luminance, eliminating the need for additional light shields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light shields are used to form cut-off lines and reduce luminance of certain zones, then regulatory compliance is achieved, but device complexity and structure complexity increase
Solution Approach 1:
The patent merges the light condensing function and cut-off line forming function into a single integrated condenser structure. The condenser includes a light condensing portion and a cut-off line forming portion that work together as one unified optical component, eliminating the need for separate light shields and reducing overall device complexity while maintaining regulatory compliance.
Solution Approach 2:
The condenser is designed to perform multiple functions simultaneously: it condenses light from LED sources, forms the low-beam light shape, creates cut-off lines, and controls luminance distribution. This multi-functional design replaces what would traditionally require multiple separate components including light shields, thereby reducing device complexity while achieving the same regulatory compliance goals.
2Reliability
If a large number of LEDs are used to control luminance changes of specific zones, then regulatory compliance is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple LED light sources into a single integrated light condensing structure. By using one condenser to collect and redirect light from multiple LEDs, the system achieves the desired luminance control and light distribution without requiring individual control of numerous LEDs, thereby reducing device complexity while maintaining regulatory compliance.
Solution Approach 2:
The condenser serves as a universal optical component that handles light from multiple LED sources simultaneously, performing light collection, condensation, and directional control functions. This multi-functional approach replaces what would otherwise require complex individual LED control circuits and additional optical components for each LED, simplifying the overall device structure.
3Reliability
If multiple LED light sources and light condensing structures are used, then regulatory compliance is achieved, but module size increases
Solution Approach 1:
The patent merges multiple light condensing structures into a single integrated condenser assembly. The condenser combines the light condensing portion, cut-off line forming portion, and reflection portion into one unified structure, significantly reducing the overall module size while maintaining the optical performance and regulatory compliance that would otherwise require multiple separate components.
Solution Approach 2:
The condenser design nests multiple functional portions within a compact structure. The cut-off line forming portion and reflection portion are integrated within the light condensing structure, creating a nested arrangement that maximizes optical functionality within minimal space, thereby reducing module size while achieving regulatory compliance.
4Reliability
If light shields are used to reduce luminance of certain zones, then regulatory compliance is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the light condensing function and luminance control function into a single molded condenser structure. This integration eliminates the need for separate light shield components and their associated assembly steps, reducing manufacturing complexity and cost while maintaining regulatory compliance through the integrated optical design.
Solution Approach 2:
The condenser is designed as a universal optical component that simultaneously performs light condensation, cut-off line formation, and luminance control functions. This multi-functionality eliminates the need for multiple separate components including light shields, reducing part count, assembly steps, and overall manufacturing cost while achieving the same regulatory compliance outcomes.
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, improves heat dissipation, and ensures compliance with regulatory luminance requirements without additional components, resulting in a more uniform light shape and lower costs.
Implementation Method 1
using transparent plastic or resin materials to refract and reflect light for controlled luminance
Implementation Method 2
using transparent plastic or resin materials to refract and reflect light for controlled luminance
Data Source
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AI summary
A condenser for a low-beam vehicle light module comprises light condensing structures (1), a cut-offline 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.