Modular Toric Projection Lens for Continuous Headlight Surface

Solution Overview

Problem

Existing headlamp technologies require custom optical systems for each vehicle model, leading to high development time and costs, as well as limited adaptability for implementing Adaptive Driving Beam (ADB) functionality, which complicates manual mode switching and visibility issues.

Innovation Solution

A modular lighting system comprising identical modules with a toric-shaped exit diopter projection lens, allowing for horizontal juxtaposition to form a continuous surface, enabling flexible assembly and reduced production costs while maintaining ADB functionality across various optical signatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If custom optical systems are designed for each vehicle model, then optical signature and ADB functionality are optimized, but development time and costs increase significantly

Engineering Contradiction:

Improveoptical signature adaptabilityVSAvoiddevelopment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The optical system is divided into modular projection lenses that can be independently designed and assembled. Each projection lens module can be independently optimized and then combined with others to create different optical signatures for various vehicle models, eliminating the need to redesign the entire optical system for each vehicle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A universal set of projection lens modules is designed that can be configured in different arrangements to serve multiple vehicle models with different optical signature requirements. The same basic modules can be adapted through different positioning and combination strategies to achieve vehicle-specific optical characteristics while maintaining ADB functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If custom optical systems are designed for each vehicle model, then optical signature and ADB functionality are optimized, but production costs increase significantly

Engineering Contradiction:

Improveoptical signature adaptabilityVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The optical system is divided into modular projection lenses that can be independently designed and assembled. Each projection lens module can be independently optimized and then combined with others to create different optical signatures for various vehicle models, eliminating the need to redesign the entire optical system for each vehicle.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of changing the physical design of projection lenses for each vehicle model, the system achieves different optical signatures by changing the positional parameters and arrangement of standardized modules. This allows cost-effective adaptation through configuration rather than redesign.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If projection lenses have precise curvatures optimized for specific light source arrangements, then light segment sharpness and shape are optimized, but system complexity and customization requirements increase

Engineering Contradiction:

Improvelight segment sharpnessVSAvoidoptical system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The optical system is divided into modular projection lenses that can be independently designed and assembled. Each projection lens module can be independently optimized and then combined with others to create different optical signatures for various vehicle models, eliminating the need to redesign the entire optical system for each vehicle.

Inventive Principle:

Principle #1Segmentation

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 system reduces production costs and time by allowing a range of headlamps to be designed with different optical signatures, improving adaptability and visibility while minimizing the risk of dazzling other road users.

Implementation Method 1

a projection lens; the modules being configured so as to project light entering the primary optical element(s) and exiting through the projection lens

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentEP3201520B1Lighting module for a device for lighting in light segments of a motor vehicle headlight

Publication Date: 2020.07.15 VALEO VISION SA

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Figure 7A~7B

AI summary

The invention relates to a lighting module for a headlight for lighting in light segments of a motor vehicle, as well as to a headlight comprising modules in accordance with the invention. The modules according to the invention are characterised in that they allow the creation of headlights that have a continuous external projection surface and implement a lighting function in segments, such as in strips, through the juxtaposition of identical modules.