One-Piece Optical Element with Dual-Axis Referencing
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Solution Overview
Problem
Automotive optical modules face challenges in maintaining stable low beam illumination due to manufacturing tolerances and temperature variations, leading to potential dazzling of oncoming drivers and requiring regular maintenance.
Innovation Solution
A one-piece optical element with distinct light inlets and a single exit, featuring mechanical referencing zones along the axis and transverse to it, ensures stable positioning and cutoff control, integrating arms for secure mounting and heat sink integration to maintain optimal light flux and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the cover element is integrated into the optical element to achieve compactness, then the device complexity is reduced, but the manufacturing precision deteriorates due to complicated management of dimensional dispersions
Solution Approach 1:
The optical element is divided into functionally distinct zones: a first contact zone for mechanical referencing along the optical axis and a second contact zone for mechanical referencing in a direction transverse to the axis. This segmentation allows independent control of positional parameters, reducing the impact of manufacturing tolerances on the cut-off position while maintaining structural integration.
2Adaptability or versatility
If the optical module is exposed to mechanical vibrations and temperature variations during use, then the device operates in real-world conditions, but the stability deteriorates due to variation in inclination of optical elements
Solution Approach 1:
The optical element is pre-configured with specifically positioned contact zones that establish stable mechanical referencing before the module is subjected to vibrations or temperature changes. The second contact zone, positioned closer to the second end, pre-compensates for potential inclination variations, ensuring the cut-off position remains stable under environmental stress without requiring active adjustment during operation.
3Ease of operation
If the position of optical elements varies over time, then the device operates flexibly, but the reliability deteriorates due to modification of illuminated area
Solution Approach 1:
The optical element performs self-alignment through its inherent mechanical referencing system. The first contact zone anchors the element along the optical axis, while the second contact zone anchors it transversely, allowing the element to maintain its optimal position autonomously without external intervention. This self-servicing mechanism ensures consistent illumination patterns over time while retaining operational flexibility.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a one-piece optical element (1) comprising a first end (4) having a plurality of light inlets (10) distinct from one another through which light rays enter the optical element (1), the optical element (1) comprising a second end (5) through which the light rays exit in a common manner, the second end (5) being configured to shape a light beam external to the optical element (1), the optical element (1) being defined by an axis (O) passing at least through the first end (4) and through the second end (5), characterized in that the optical element (1) comprises at least a first contact zone (11) dedicated to its mechanical referencing along the axis (O) and at least a second contact zone (12) dedicated to its mechanical referencing along a direction (D1) transverse to the axis (O),the second contact zone (12) being closer to the second end (5) than to the first end (4).