Monolithic Headlight Optic Array for Soft Gradient Light Distribution
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Solution Overview
Problem
Current vehicle headlight optics are costly to manufacture and lack a soft gradient in the transition region from illuminated to non-illuminated areas, leading to inefficient light distribution.
Innovation Solution
A monolithically pressed primary optic array of inorganic glass with multiple interconnected primary optics and connection webs, where the webs are not directly lit but allow scattered light to impinge on them, forming an array that enhances light distribution by positioning each primary optic to engage with others, creating a soft gradient between illuminated and non-illuminated regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate primary optics are used in vehicle headlights, then manufacturing flexibility is maintained, but manufacturing costs increase and assembly complexity increases
Solution Approach 1:
The patent merges multiple separate primary optics into a single monolithically pressed array structure. The array comprises multiple primary optics integrated into one piece of transparent material, eliminating the need for separate manufacturing and assembly of individual optics. This integration directly reduces manufacturing costs and simplifies assembly while maintaining the optical functionality of each individual optic element.
Solution Approach 2:
Within the monolithic array structure, the patent segments the optical functionality into distinct primary optic elements that are optically independent. Each primary optic within the array can be designed and optimized separately for specific lighting functions, while being manufactured as a single integrated unit. This segmentation allows functional differentiation without requiring separate physical components.
2Illumination intensity
If traditional headlight optics are used, then manufacturing processes are simple, but a soft gradient in the transition region from illuminated to non-illuminated areas is not achieved
Solution Approach 1:
The patent implements local quality variations within the monolithic array by positioning specific primary optics with different optical characteristics at different locations. The array includes primary optics optimized for various functions (e.g., high beam, low beam, fog light) at specific positions, creating localized optical properties that achieve the desired soft gradient effects in different regions of the headlight beam pattern.
Solution Approach 2:
The patent introduces connection webs as intermediary structures between primary optics within the array. These webs serve as optical mediators that facilitate the soft gradient transition between illuminated and non-illuminated areas by controlling light propagation and scattering between adjacent primary optics, thereby achieving smooth transitions without requiring complex manufacturing processes.
3Manufacturing precision
If multiple separate primary optics are assembled, then individual optic optimization is possible, but manufacturing costs and assembly time increase
Solution Approach 1:
The patent combines multiple primary optics into a single monolithically pressed array, eliminating the need for separate assembly operations. The precise positioning of each primary optic within the array is achieved during the single pressing operation, ensuring high positioning precision while dramatically improving manufacturing efficiency by producing the entire assembly in one manufacturing step rather than assembling multiple separate components.
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 manufacturing costs and achieves a soft gradient in the transition region, improving light distribution by positioning each primary optic to engage with others, enhancing the vehicle headlight's illumination efficiency.
Implementation Method 1
it may be provided for that portions of scattered or diffused light impinge at the interior of a web and/or a connection web
Implementation Method 2
the first primary optic, the second primary optic, the third primary optic and/or the fourth primary optic comprise/s, between its/their respective light entry face/s and its/their light exit face/s, a press-molded surface, in particular for the total reflection of light irradiated into the light entry surface
Data Source
AI summary
The invention relates to an optical element for a vehicle headlight, in particular a motor vehicle headlight, having a first head lens array which is a compressed as a single piece from a transparent material and at least one second head lens array which is compressed as a single piece from the same or another transparent material. Said first head lens array and the second head lens array have respectively a connecting web which connects the at least one first head lens to a second head lens.