Micro-projection Headlight Module with Integrated Optics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Micro-projection light modules for vehicle headlights face challenges with low optical efficiency and high tolerance sensitivity due to multiple optically relevant structural components, leading to light losses and positioning inaccuracies that result in blurred light patterns.
Innovation Solution
A micro-projection light module design featuring an ancillary optics arrangement with a planar boundary surface, where the light source emits light in parallel, reducing reflections and incorporating a one-piece design for the ancillary optics and entry optics to minimize refractive faces, along with micro-optics systems that focus light into focal points and use screen devices to correct aberrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple optically relevant structural components are used in the micro-projection light module, then the light distribution can be shaped and projected, but optical efficiency decreases due to light reflections at boundary surfaces
Solution Approach 1:
The patent integrates the ancillary optics arrangement and entry optics into a single structural component, eliminating the boundary surface between them. This merging reduces the number of interfaces where light reflections occur, thereby improving optical efficiency while maintaining the functional capabilities of light shaping and projection.
2Manufacturing precision
If multiple structural components are used in the micro-projection light module, then light distribution can be controlled, but tolerance sensitivity increases leading to blurred light patterns
Solution Approach 1:
By combining the ancillary optics arrangement and entry optics into one integrated component, the patent reduces the number of separate parts that require precise positioning. This integration eliminates positioning tolerances between multiple components, thereby reducing tolerance sensitivity and preventing blurred light patterns while maintaining light distribution control.
3Ease of manufacture
If multiple optically relevant structural components are used, then light can be directed and projected, but production cost increases
Solution Approach 1:
The integration of ancillary optics and entry optics into a single component reduces the total part count, which simplifies manufacturing processes, reduces assembly requirements, and lowers production costs. The merged component can be manufactured as a single piece, eliminating the need for multiple precision manufacturing operations and assembly steps.
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 enhances optical efficiency, reduces production costs, and decreases tolerance sensitivity, resulting in sharper and more consistent light patterns with improved positioning flexibility.
Implementation Method 1
the ancillary optics arrangement being designed in such a way that the light emitted therefrom is directed substantially in parallel
Implementation Method 2
there are substantially no reflections at an oblique angle, whereby the light losses can be kept low
Implementation Method 3
each micro entry optics is paired with precisely one micro exit optics... the light pre-shaped by the micro entry optics is imaged by the micro exit optics
Implementation Method 4
the micro entry optics are designed in such a way and/or the micro entry optics and the micro exit optics are arranged relative to one another in such a way
Implementation Method 5
the light pre-shaped by the micro entry optics is imaged by the micro exit optics into an area in front of the motor vehicle in the form of at least one light distribution
Data Source
AI summary
A micro-projection light module (1) for a vehicle headlight, comprising at least one light source (2) and at least one projection arrangement (3) which images the light emitted from the at least one light source (2) into an area in front of the motor vehicle in the form of at least one light distribution, wherein the projection arrangement (3) comprises an entry optics (30) having one, two, or more micro entry optics (31) preferably arranged in an array, and an exit optics (40) having one, two, or more micro exit optics (41) preferably arranged in an array, wherein each micro entry optics (31) is paired with precisely one micro exit optics (41), wherein the micro entry optics (31) are designed in such a way and/or the micro entry optics (31) and the micro exit optics (41) are arranged relative to one another in such a way that substantially all the light emitted from a micro entry optics (31) enters precisely only into the paired micro exit optics (41), and wherein the light pre-shaped by the micro entry optics (31) is imaged by the micro exit optics (41) into an area in front of the motor vehicle in the form of at least one light distribution (LV1-LV5; GLV), wherein the at least one light source (2) is paired with an ancillary optics arrangement (4), the at least one light source (2) irradiates the light emitted therefrom into said at least one ancillary optics arrangement (4), said ancillary optics arrangement (4) being designed in such a way that the light emitted therefrom is directed substantially in parallel, and the entry optics (30) having at least one planar boundary surface (31′), wherein the at least one planar boundary surface (31′) faces the ancillary optics arrangement (4).