Modular Projection Light Module Design Freedom
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Solution Overview
Problem
Current projection light modules for motor vehicle headlights are limited in design flexibility due to technical constraints, leading to high development and manufacturing costs, as changes in the converging lens require significant redevelopment of the entire module.
Innovation Solution
A modular system for projection light modules, where the most visible components relevant to appearance are combined in a variable assembly, while less visible technical components remain unchanged, allowing for design freedom without complete redevelopment, using a diaphragm unit and lens holder unit in a second assembly, and a light source unit and lens unit in a first assembly, with a defined interface and plastic lenses for cost-effective and flexible production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the converging lens shape is changed to achieve design freedom in headlight appearance, then the appearance differentiation is improved, but the development cost and manufacturing complexity increase significantly
Solution Approach 1:
The projection light module is divided into two separate assemblies: a first assembly containing the light source unit and aperture unit, and a second assembly containing the lens unit and lens holder unit. This segmentation allows the lens unit to be independently designed and modified without affecting the technical components, enabling appearance differentiation while maintaining manufacturing efficiency.
2Ease of manufacture
If pre-assembled projection light modules are used for mass production, then manufacturing cost is reduced, but design flexibility and appearance differentiation are limited
Solution Approach 1:
The module is segmented into standardized first assemblies (light source unit + aperture unit) that can be mass-produced, and variable second assemblies (lens unit + lens holder unit) that can be customized. This allows the technical core to be manufactured efficiently while the appearance-critical lens components can be varied for different headlight designs.
Solution Approach 2:
The first assembly with light source unit and aperture unit is designed as a universal platform that can be combined with different lens units to create multiple headlight appearances. This multi-functional design allows a single standardized assembly to serve multiple design purposes.
3Ease of manufacture
If the lens unit is integrated with the light source unit and aperture unit in a single assembly, then adjustment for optical function is simplified, but the complexity of the variable component increases and reduces the benefits of high-volume production
Solution Approach 1:
The system is divided into two assemblies with a defined interface. The first assembly (light source unit + aperture unit) remains standardized for high-volume production, while the second assembly (lens unit + lens holder unit) is designed to interface with the first assembly through standardized mounting structures, allowing independent optimization of both assemblies.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The projection light module (10) comprises an assembly, which has a light source unit (2) with semiconductor light sources, and another assembly with a lens unit (6). The former assembly is configured to hold the latter assembly in the projection light module. The former assembly is configured to hold in the projection light module without changing an embodiment of the latter assembly or another embodiment of the latter assembly different from the former embodiment.