Modular Light Module with Precision Fastening for Headlight Alignment
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Solution Overview
Problem
Existing light modules for motor vehicle headlights require precise alignment and calibration of optically functional parts, which is costly and labor-intensive, and can lead to inefficiencies in light distribution due to imprecise positioning of semiconductor light sources and optics, resulting in reduced light coupling and potential color fringes.
Innovation Solution
A modular light module structure comprising preassembled structural units, including a light source unit, primary optics unit, and secondary optics unit, with precise fastening devices allowing for accurate assembly and calibration, enabling efficient alignment and minimization of dispersion effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise alignment and calibration of optically functional parts are implemented, then light distribution efficiency is improved, but manufacturing cost and labor intensity increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling and pre-calibrating optical components (light guides, lenses, reflectors) with semiconductor light sources in modular units before final assembly. This allows alignment and calibration to be performed in advance under controlled conditions, ensuring high precision while simplifying the final manufacturing process. The modular design enables these components to be manufactured and calibrated separately, then integrated as pre-configured modules.
Solution Approach 2:
The patent segments the headlight system into multiple modular units, each containing specific optical components and light sources. This segmentation allows each module to be independently manufactured, aligned, and calibrated, reducing the overall manufacturing complexity while maintaining high precision. The modular architecture enables parallel production and assembly of multiple modules with consistent optical performance.
2Loss of energy
If precise positioning of semiconductor light sources and optics is achieved, then light coupling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the semiconductor light source, primary optics (light guides, lenses, reflectors), and positioning structures into integrated modular units. This combination ensures precise positioning and optimal light coupling efficiency while reducing overall device complexity through functional integration. The merged design eliminates the need for separate adjustment mechanisms, as the components are pre-positioned and fixed together in the optimal configuration.
3Productivity
If modular preassembled structural units are used, then assembly process is simplified, but positioning precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling optical components with precise positioning features and calibration data before modular unit formation. This preliminary preparation ensures that when modules are quickly assembled during final production, the pre-established positioning features maintain high positioning accuracy without requiring complex real-time adjustment mechanisms during assembly.
Solution Approach 2:
The patent uses standardized positioning features and reference geometries that are consistently replicated across all modular units. This copying approach ensures that each module can be rapidly assembled with high positioning accuracy by simply matching the standardized features, eliminating the need for complex individual positioning procedures for each module.
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 modular design simplifies the assembly process, reduces manufacturing errors, and ensures precise light distribution, enhancing the efficiency and cost-effectiveness of light module production while maintaining sensitive calibration for optimal performance in various headlight configurations.
Implementation Method 1
a lens device (48) for projecting or imaging the light distribution occurring during operation of the light module on the light exit surfaces (36) into a light beam distribution in an area in front of the light module (10)
Data Source
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AI summary
The module has a light source unit (12), a primary optic unit (14) and a secondary optic unit (18) formed as pre-mounted components and joined for final assembly of the module. The secondary optic unit includes a lens device (48) e.g. collecting lens, for projecting light distribution into radiation light distribution of the module. Bolt-like fastening sections (56) and cylinder openings (58) position-precisely fasten the primary optic and source units at each other. An opening (60) and a pin-like projection position-precisely fasten the secondary optic unit relative to the primary optic unit.