Offset Emissive Matrix for Vehicle Headlamp DMD Reliability
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Solution Overview
Problem
High-resolution Digital Micromirror Device (DMD) type light modules for motor vehicle headlamps are fragile due to the high number of sensitive micromirrors, leading to increased production costs and risk of malfunction, making their use in headlamps difficult.
Innovation Solution
A light module with a matrix of emissive elements and active elements offset from each other, where each active element is illuminated by multiple emissive elements, allowing for reduced number of active elements required to achieve the same image resolution, thereby reducing costs and increasing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high-resolution DMD-type light module is used to project pixelated images, then the image resolution is improved, but the number of micromirrors increases leading to increased fragility and production costs
Solution Approach 1:
The invention segments the light source into multiple independent light-emitting elements arranged in a matrix, where each element can be selectively activated. This segmentation allows the system to achieve high-resolution pixelated image projection without requiring a proportional increase in the number of micromirrors, as multiple light elements can illuminate the same micromirror area. The segmentation of the light source resolves the contradiction by decoupling the resolution achievement from micromirror quantity, thereby maintaining reliability while improving image resolution.
Solution Approach 2:
The invention introduces a spatial offset between the light-emitting elements matrix and the micromirrors matrix along the optical axis, creating a three-dimensional arrangement. This dimensional change allows each micromirror to be illuminated by multiple light-emitting elements simultaneously, effectively increasing the system's resolution capability without proportionally increasing the micromirror count. This spatial reconfiguration resolves the contradiction by adding a dimensional degree of freedom to the system design.
2Measurement precision
If the number of micromirrors is increased to achieve higher image resolution, then the pixelated image quality is improved, but the production costs and device complexity increase
Solution Approach 1:
The light source is segmented into multiple independently controllable light-emitting elements arranged in a matrix configuration. This segmentation enables the system to generate high-quality pixelated images by selectively activating specific light elements, thereby achieving fine image resolution without requiring a proportionally large number of micromirors. The segmented light source approach reduces device complexity by decoupling image resolution from micromirror quantity.
Solution Approach 2:
Each micromirror in the matrix is designed to be universally illuminated by multiple light-emitting elements, allowing a single micromirror to serve multiple functional purposes in image generation. This multi-functionality approach enables the system to achieve high image quality with fewer micromirrors, as each micromirror can contribute to multiple pixel positions in the projected image through illumination from different light elements.
3Measurement precision
If more micromirrors are used to increase image resolution, then the projection detail is improved, but the risk of malfunction and breakage increases
Solution Approach 1:
The invention segments the illumination function across multiple light-emitting elements rather than relying on a large number of micromirrors. Each light-emitting element can be independently controlled and replaced if needed, distributing the system's functional load and reducing the criticality of each individual micromirror. This segmentation approach maintains high projection detail while improving overall system reliability by reducing micromirror dependency.
Solution Approach 2:
The invention creates multiple optical paths by having multiple light-emitting elements illuminate the same micromirror region, effectively creating redundant illumination copies. This copying approach ensures that if one light-emitting element fails, other elements can continue to illuminate the micromirrors and maintain image projection functionality, thereby improving system reliability while maintaining projection detail.
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 configuration allows for the projection of pixelated images with fewer active elements, resulting in a smaller, cheaper, and more reliable light module with increased micromirror size, reducing the risk of breakage and production costs.
Implementation Method 1
a reflector 4, configured to deflect the beam's rays onto a micromirror array 5. The light source is positioned near the image focus of the reflector, and the micromirror array is also positioned near the image focus of the reflector, so that the rays reflected by the internal reflective surface of the reflector are concentrated onto the micromirror array 5
Implementation Method 2
the rays reflected by the internal reflective surface of the reflector are concentrated onto the micromirror array 5, illuminating all the micromirrors
Implementation Method 3
each micromirror is mounted to pivot around an axis, between an active position in which the micromirror reflects the incident light beam towards the projection optical system, and a passive position in which the micromirror reflects the incident light beam towards a light-absorbing element
Implementation Method 4
Once reflected by at least some of the micromirrors, the light beam passes through a diopter 6 of the light module 1 to project the light beam
Data Source
Figure 1~5
Figure 6~7D
Figure 8~9
AI summary
The invention relates to a lighting module for a motor vehicle, configured to project a light beam forming a pixelated image. The lighting module comprises a light source (102) and a light processing device (200) for the light emitted by the light source (102), and includes an array (201) of active elements (202) configured to process at least a portion of the light beam emitted by the light source (102) so as to form the pixelated image. The light source (102) includes an array of emitting elements (134) among which at least two emitting elements are selectively activatable, and the array of emitting elements (134) and active elements (202) are offset from each other such that each active element (202) is arranged across a portion of the light beam emitted by an emitting element (134).