Optical Assembly Attachment for Partial High-Beam Headlight Module
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Solution Overview
Problem
The existing optical attachment assemblies for motor vehicle headlights face challenges in achieving precise light guide positioning and surface quality without using expensive materials, while also requiring a play-free connection with minimal component costs, especially when integrating LED light sources for partial high beam functions.
Innovation Solution
The optical attachment assembly features a mirror cover elastically locked between the base body and insert, with the insert positioned between the mirror cover and base body, utilizing a flexible material and spring-elastic locking structures to achieve a play-free connection and precise light guide alignment, allowing for smaller light exit surface distances and efficient light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the base body and insert are manufactured as a single piece, then the structure is simpler, but the accessibility for polishing light guide cavities and avoiding sharp knife edges is reduced
Solution Approach 1:
The auxiliary optics base body is divided into two separate components: a base body and an insert that can be manufactured independently. This segmentation allows the insert to be accessed and polished separately from the base body, improving manufacturing accessibility while avoiding the need for complex single-piece construction with sharp knife edges
2Manufacturing precision
If expensive light guide materials such as silicone are used, then the surface quality of light guide surfaces is improved, but the material cost increases
Solution Approach 1:
By separating the base body and insert into distinct components, the insert can be manufactured with precise surface quality requirements using cost-effective materials, while the base body can be optimized for structural requirements. This eliminates the need to use expensive silicone materials throughout the entire assembly
Solution Approach 2:
Different material properties can be applied to different parts: the insert, which requires high surface quality for light guide cavities, can use materials optimized for optical surfaces, while the base body can use materials optimized for structural support and cost-effectiveness
3Stability of the object's composition
If the mirror cover is rigidly connected to the base body, then the connection is stable, but the adaptability to accommodate the insert and achieve play-free connection is reduced
Solution Approach 1:
The mirror cover is constructed from flexible material that can elastically deform during assembly to accommodate the insert and base body, then maintains a stable, play-free connection once assembled. The flexibility allows adaptability during assembly while providing stability in the final configuration
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 ensures a cost-effective, play-free connection with improved surface quality and precise light guide positioning, enhancing the optical performance and energy efficiency of motor vehicle headlights with LED light sources by minimizing material costs and avoiding production complexities.
Implementation Method 1
the mirror cover is elastically clamped and locked to the base body at two different locations spanning the insert
Implementation Method 2
spring-elastic locking structures which are designed to lock with locking structures of the base body
Data Source
Figure 1
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AI summary
An optical assembly attachment for a partial high-beam light module for a motor vehicle headlight is presented. Such an optical assembly attachment comprises an optical assembly attachment main body containing first optical waveguides, and comprises a separate insert part containing second optical waveguides. An optical waveguide that is closest adjacent to a first optical waveguide in a series is a second optical waveguide, and an optical waveguide that is closest adjacent to a second optical waveguide in the series is a first optical waveguide. The insert is sandwiched between the reflecting light shielding member and the main body. The reflecting light shielding member is resiliently snap-fitted to the main body at two mutually different locations, thereby spanning the insert.