Optical Module Internal Gear Motor Mounting
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Solution Overview
Problem
Existing optical modules for motor vehicle headlamps face issues with bulkiness and heat resistance due to external toothed gears and plastic motor supports, which are heavy, expensive, and prone to damage from concentrated solar heat.
Innovation Solution
The optical module employs an internal toothed gear mechanism with a motor positioned under the cut-off bar's axis of rotation, reducing the module's longitudinal size and using a metal motor support with a heat-resistant, light-colored plastic connection area to mitigate heat exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an external toothed gear is used to drive the cut-off bar, then the cutting-off function is achieved, but the longitudinal size and bulk of the optical module increases
Solution Approach 1:
The patent inverts the traditional external toothed gear configuration by using an internal toothed gear where the teeth are located inside the gear body rather than on the outside. This inversion allows the gear to be positioned within the longitudinal dimension of the cut-off bar, significantly reducing the longitudinal size of the optical module while maintaining the cutting-off function
Solution Approach 2:
The patent transitions from a lateral gear arrangement (external teeth on the side of the cut-off bar) to a longitudinal arrangement (internal teeth within the bar's longitudinal dimension). This dimensional repositioning reduces the bulk in the height direction and optimizes the longitudinal space utilization
2Temperature
If a metal motor support is used, then heat resistance is improved, but the weight and cost increase
Solution Approach 1:
The patent applies local quality by using metal material specifically for the motor support where heat resistance is critical, while other parts of the optical module continue to use plastic materials. This localized material selection provides heat resistance exactly where needed (at the motor support position) without increasing the weight and cost of the entire module
Solution Approach 2:
The patent converts the harmful concentrated solar heat into a beneficial design feature by positioning the metal motor support to naturally block and reflect heat away from plastic components. The heat that would otherwise damage plastic parts is now used to demonstrate the effectiveness of the thermal management design, where the metal support acts as a heat shield
3Object-affected harmful factors
If a metal heat shield is added between the lens and motor support, then heat protection is improved, but the weight, cost and bulk increase
Solution Approach 1:
The patent makes the motor support multi-functional by giving it both mechanical support functions (holding the motor and transmitting drive force) and thermal protection functions (shielding plastic components from heat). This eliminates the need for a separate heat shield component, reducing weight, cost and bulk while maintaining heat protection
Solution Approach 2:
The patent merges the heat shield function with the motor support structure. Instead of having separate components for support and thermal protection, the motor support is designed to perform both functions simultaneously, consolidating multiple protective roles into a single integrated component
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 minimizes the optical module's bulk and protects the motor from heat damage while maintaining efficient light beam control, offering a cost-effective and compact solution for headlamp functionality.
Implementation Method 1
a pinion of the motor drives a bar for cutting off a light beam by means of an internal toothed gear
Implementation Method 2
a light source which projects light onto a reflector. The light is then reflected on a lens in order to be reversed and returned in the form of a light beam
Implementation Method 3
the optical module can be subjected to the heat of the solar rays which enter the optical module via the lens, for example when the vehicle is parked in direct sunlight. The rays passing through the lens indeed converge towards the motor support and thus concentrate the heat on the latter
Data Source
Figure 1
Figure 2~3
AI summary
The module has a lens, and a motor that is mounted in the optical module on a driving support (40). A pinion of the motor drives a disconnecting strip of a light beam by utilizing a gear (14) with internal teeth. A gear ratio between the pinion of the motor and the gear is one-by-three. The motor is located under an axis of rotation of the disconnecting strip. The disconnecting strip presents a longitudinal obstruction, where the motor is located inside the longitudinal obstruction of the disconnecting strip.