Low-Beam Projection Unit With Integrated Reflection Cut-Off Plate

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Solution Overview

Problem

Existing vehicle lamp illumination systems face issues with large size due to bifocal reflectors, complex assembly, high weight, and manufacturing errors leading to performance fluctuations, and inefficient luminous efficacy due to light shield structures.

Innovation Solution

A projection unit comprising a light source, reflection plate, and optical lens replaces traditional reflectors and light shields, utilizing a reflection plate with a designed reflection boundary to form a bright and dark cut-off line, and optionally incorporating a secondary light distribution member to enhance luminosity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a bifocal reflector like an ellipsoidal surface is used, then the illumination function is achieved, but the depth increases and occupies large space

Engineering Contradiction:

Improveillumination functionVSAvoiddepth

Core Design Contradiction:

Illumination intensityVSLength of stationary object

Solution Approach 1:

The patent merges the reflector and light shield plate into a single integrated component. The reflection plate incorporates both the reflective surface for illuminating the road and the light shielding function to block excessive light, eliminating the need for separate reflector and light shield plate assemblies. This integration significantly reduces the overall depth and space occupation of the vehicle lamp while maintaining the required illumination function.

Inventive Principle:

Principle #5Merging (Combining)

2Illumination intensity

If traditional reflector and light shield plate are used, then the bright and dark cut-off line is formed, but the number of parts increases and assembly becomes complicated

Engineering Contradiction:

Improvebright and dark cut-off lineVSAvoidnumber of parts

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The reflection plate integrates both the reflective surface for illuminating the road and the light shielding function to block excessive light, eliminating the need for separate reflector and light shield plate assemblies. This integration significantly reduces the overall depth and space occupation of the vehicle lamp while maintaining the required illumination function.

Inventive Principle:

Principle #5Merging (Combining)

3Illumination intensity

If light shield structure is used to form cut-off line, then the bright and dark boundary is achieved, but the luminous efficacy decreases

Engineering Contradiction:

Improvebright and dark cut-off lineVSAvoidluminous efficacy

Core Design Contradiction:

Illumination intensityVSLoss of energy

Solution Approach 1:

The reflection plate features a locally varied reflective coefficient, with different regions having different reflectivity characteristics. The first reflection region has a higher reflective coefficient than the second reflection region, allowing precise control of light distribution. This local quality variation enables the formation of the bright and dark cut-off line while minimizing energy loss by directing light efficiently to where it is needed.

Inventive Principle:

Principle #3Local quality

4Reliability

If multiple parts are assembled, then the illumination system is complete, but manufacturing errors accumulate and performance fluctuates

Engineering Contradiction:

Improveillumination system completenessVSAvoidaccumulative errors

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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 reduces the vehicle lamp's size and space, simplifies assembly, minimizes performance fluctuations, and enhances luminous efficacy while maintaining the required cut-off line functionality.

Implementation Method 1

a light source (50) and an optical lens (54) in an emergent direction of a low beam light

Methodology Applied

Scientific EffectLight emission from LED: Light Emitting Diode

Implementation Method 2

A reflection plate (52) is arranged in a direction of an optical axis of the light source (50), and light rays reflected by the reflection plate (52) illuminate a road surface through the optical lens (54)

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

the light rays reflected by the reflection plate (52) illuminate a road surface through the optical lens (54)

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS20260036274A1Projection unit for low beam light of vehicle and vehicle lamp using same

Publication Date: 2026.02.05 HASCO VISION TECHNOLOGY CO LTD

AI summary

Disclosed are a projection unit for a low beam light of a vehicle, and a vehicle lamp. The projection unit is composed of a light source, a reflection plate and an optical lens. The reflection plate is provided with a reflection boundary corresponding to the shape of a bright and dark cut-off line required by an illumination light shape of a vehicle lamp system. The reflection boundary is arranged near a focus of the optical lens, the light source illuminates the reflection plate, and light rays reflected by the reflection plate form an initial illumination light shape, then form a secondary illumination light shape by the optical lens and illuminate a road surface to form a final illumination light shape with a bright and dark cut-off line. The projection unit reduces the size and space of a vehicle lamp, thus being advantageous for a flat design of the vehicle lamp.