Optical Element Lens Carrier LED Headlight Efficiency
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Solution Overview
Problem
LED headlights in automobile applications face reduced light efficiency due to high directivity of light emission, complex optical alignment, and light absorption by conventional reflective materials, which are not optimized for the precision required by LED technology.
Innovation Solution
An optical element with a specific light entering and exiting surface design, including curved portions and a lens carrier with precise positioning structures, to enhance light efficiency and align with regulatory cut-off lines, such as the ECE R112 code, and a lens carrier that positions the light source unit and lens for optimal light utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional reflective materials and shielding elements are used in LED headlight modules, then the optical alignment can be simplified, but light efficiency is reduced due to light absorption and blocking
Solution Approach 1:
The patent removes conventional reflective materials and shielding elements from the optical path. Instead of using separate reflective surfaces and cut-off line structures, the invention integrates the cut-off line formation directly into the lens surface geometry, eliminating the harmful reflective materials that absorb light and the shielding elements that block light.
Solution Approach 2:
The patent combines the functions of light shaping and cut-off line formation into a single integrated lens structure. The third portion of the lens directly forms the cut-off line while also shaping the light distribution, merging what would traditionally require separate optical elements into one unified component.
2Use of energy by moving object
If LED is used to replace halogen bulb or xenon lamp in conventional headlight module, then energy saving and environmental protection are improved, but light efficiency is not satisfied due to precision alignment requirements
Solution Approach 1:
The lens structure is designed to automatically form the required cut-off line and light distribution pattern based on the LED's light emission characteristics. The inclined third portion of the lens self-adjusts the light path to comply with ECE R112 regulations without requiring complex external alignment mechanisms or additional optical elements.
Solution Approach 2:
The patent optimizes the lens parameters (curvature, inclination angle, surface geometry) to match the high directivity characteristics of LED light emission. By changing the optical parameters of the lens to suit LED-specific properties rather than conventional bulb properties, the system achieves both energy efficiency and high light utilization.
3Volume of stationary object
If conventional headlight module design is used with LED, then the module volume can be maintained, but optical alignment becomes complicated and light efficiency is reduced
Solution Approach 1:
The lens is designed to perform multiple functions simultaneously: light focusing, light distribution shaping, and cut-off line formation. This multi-functional lens replaces what would traditionally require multiple separate optical elements, maintaining compact module volume while improving light efficiency through integrated optical design.
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
The solution improves light use efficiency and module efficiency by forming a cut-off line compliant with regulations, reducing the optical module's volume and ensuring precise alignment for enhanced light distribution, thus increasing overall light efficiency.
Implementation Method 1
The lens is disposed on a path of the light... The optical element is disposed on the path of the light, and the lens is disposed between the light source unit and the optical element
Implementation Method 2
the first extending direction is inclined with respect to the second extending direction... so that a cut-off line may be formed 25 meters away from the optical module or the optical element
Data Source
AI summary
An optical element including a light entering surface and a light exiting surface is provided. The light exiting surface is opposite to the light entering surface, and includes a first portion, a second portion, and a third portion. The first portion is a curved surface. The second portion is a curved surface and spaced from the first portion by a step difference. The third portion extends from the first portion to the second portion along a first extending direction, wherein the first portion extends along a second extending direction, and the first extending direction is inclined with respect to the second extending direction. An optical module and a lens carrier are also provided.