Nested Light Guide Structure for Vehicle Headlight Assembly
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Solution Overview
Problem
Existing motor vehicle lighting systems face challenges in efficiently illuminating the side of the road beyond the adjacent lane, leading to potential safety hazards due to the complexity and cost of separate light guides, as well as issues with air gaps and junction radii in integrated systems.
Innovation Solution
A lighting system with light guides distributed over two nested guide parts of complementary shapes, reducing the number of parts and adjustment operations, and using an adhesive to secure and align the guides without distorting light, while avoiding parasitic coupling and air pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light guides are made in separate parts, then each guide can be individually coupled to light sources, but the number of fixing operations and adjustment operations increases significantly
Solution Approach 1:
The patent combines multiple separate light guides into a single integrated light guide structure that couples to multiple light sources simultaneously. This merging eliminates the need for multiple individual fixing operations and reduces the number of adjustment operations required during assembly, directly resolving the contradiction between individual guide coupling and assembly complexity.
Solution Approach 2:
The integrated light guide structure serves multiple functions: it couples to multiple light sources, guides light from each source, and provides structural support all in one component. This multi-functionality reduces the overall number of parts and assembly operations while maintaining the capability to individually address each light source.
2Adaptability or versatility
If multiple separate light guides are used, then selective lighting of scene zones is achieved, but handling and installation becomes difficult due to small dimensions and numerous parts
Solution Approach 1:
By merging multiple small light guides into one integrated structure, the patent maintains the selective lighting capability through internal segmentation while dramatically improving handleability. The larger integrated component is much easier to handle and install compared to numerous small separate guides, directly resolving this contradiction.
3Device complexity
If light guides are integrated with optical projection device, then number of parts is reduced, but air gaps and junction radii issues arise
Solution Approach 1:
The patent integrates the light guide with the optical projection device into a unified structure, reducing the number of parts while designing the integration to minimize air gaps and optimize junction radii. The integrated design allows for continuous material transitions and eliminates interfaces that would create problematic air gaps, resolving the contradiction between part reduction and manufacturing precision.
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
This solution simplifies the handling and installation of light guides, reduces manufacturing costs, and enhances light intensity and beam quality by minimizing air gaps and ensuring consistent light spots, thus improving road illumination without compromising the system's operation.
Implementation Method 1
using an adhesive to secure and align the guides without distorting light
Implementation Method 2
light guides, each light guide being coupled with one of the light sources, the light guides being arranged so as to form, from the light emitted by the light sources
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A lighting system (1) for a motor vehicle comprising at least one lighting module (2) including: - light sources (6), each having a generally rectangular light-emitting face, the light-emitting faces being centered on the same line defining an alignment direction (16) of the light sources (6), and - an optical projection device (10). The lighting module (2) further includes light guides (18), each guide being coupled to one of the light sources (6). The guides are distributed on first (20) and second (22) guide pieces of complementary shapes, nested one inside the other. The first guide piece (20) is positioned opposite the light-emitting faces, and the second guide piece (22) is mounted on a free surface (12) of the optical projection device (10).The lighting system (1) is arranged so as to form a light spot (26) per light source, each light spot (26) having a light strip shape.