One-Piece Primary Optics for Flexible Matrix Headlamp Light Distribution
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Solution Overview
Problem
Current matrix headlights face limitations in variability and flexibility of light distribution design, with high complexity and cost due to numerous optical components and demanding manufacturing and positioning tolerances, which can lead to excessive scattered light and non-compliance with legal requirements for partial high beam operation.
Innovation Solution
A headlight design featuring a one-piece primary optics field with differently shaped lens-shaped sections, arranged to minimize total internal reflections and reduce component complexity, using a robust and cost-effective material like PMMA or PC, allowing for flexible and variable matrix light distributions with fewer optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate optical components are used to achieve flexible matrix light distributions, then adaptability and versatility are improved, but device complexity and manufacturing precision requirements increase significantly
Solution Approach 1:
The patent merges multiple separate optical components into a single integrated optical element. The one-piece primary optics field combines multiple lens-shaped sections that would traditionally be separate components, reducing assembly complexity and improving manufacturing precision while maintaining the ability to generate flexible matrix light distributions through the different shaped sections
2Manufacturing precision
If traditional primary optics with total internal reflection geometries are used, then light distribution control is improved, but manufacturing precision and positioning tolerances become extremely demanding
Solution Approach 1:
The patent replaces the mechanical/optical system based on total internal reflection with a refractive optical system. Instead of relying on precise geometric configurations that require total internal reflection, the invention uses lens-shaped sections with different shapes that refract light to achieve the desired matrix light distributions, significantly reducing positioning tolerance requirements
3Reliability
If expensive materials like silicone are used for primary optics, then optical performance is improved, but cost and robustness are worsened
Solution Approach 1:
The patent changes the material parameter from expensive silicone to more cost-effective and robust materials. The one-piece primary optics field can be manufactured from materials that are easier to process and more robust, while the different shaped lens sections maintain the necessary optical performance through their geometric design rather than material properties
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 design achieves high variability and flexibility in matrix light distributions with reduced manufacturing complexity and cost, minimizing scattered light and ensuring compliance with legal requirements by using a single component with adjustable lens elements, thus enhancing the robustness and cost-effectiveness of the system.
Implementation Method 1
Each primary optical sub-area has a light-entry surface facing a semiconductor light source and a light-emission surface facing the secondary optical array. Exactly one principal emission direction of exactly one semiconductor light source passes through the light-entry surface and the light-emission surface of each primary optical sub-area.
Data Source
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AI summary
A headlight with semiconductor light sources, a one-piece primary optical field and a secondary optic is presented, wherein the semiconductor light sources are arranged in at least one row, wherein the primary optical field has a primary optic sub-area for each semiconductor light source, which are also arranged in one row, wherein each primary optic sub-area has a light-intake surface and a light-emission surface, wherein the light-intake surface and the light-emission surface and wherein the secondary optic is configured to image the light-emission surfaces of the primary optic sub-areas in a light distribution of the headlight.The headlight is characterized by the fact that the light entry surfaces and the light exit surfaces of the primary optic sub-areas are freeform surfaces that are separated from each other by sharp edges lying between them, and wherein the light exit surfaces of primary optic sub-areas not located at the beginning or end of a row differ from each other in their shape.