Optical Module Transparent Block Reflective Coating
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Solution Overview
Problem
Existing optical modules for automotive lighting devices face challenges in achieving improved optical performance, particularly in the emission of road-type beams without interruption, and in maximizing light intensity while minimizing parasitic effects from support materials.
Innovation Solution
The introduction of a transparent block with a reflective coating between the light source and the dioptric element, which deflects light rays to enhance beam intensity and distribution, and can be designed to be minimally intrusive or control light deviation, replacing traditional metal supports and static masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a traditional metal support or static mask is used to deflect light rays, then the beam intensity can be controlled, but parasitic effects are introduced and optical performance is reduced
Solution Approach 1:
A transparent block is introduced as an intermediary element between the light source and the reflector. This transparent block supports the reflective coating and deflects light rays without introducing the parasitic effects associated with traditional metal supports. The transparent material allows light to pass through while providing structural support for the reflective surface, thereby mediating between the need for light deflection and the need to avoid optical interference.
Solution Approach 2:
The patent replaces traditional metal mechanical supports with a transparent block that can be made of optical-grade materials. This substitution eliminates the mechanical parasitic effects (reflection, absorption, scattering) caused by metal supports while maintaining the structural function of supporting the reflective coating. The transparent block can be precisely manufactured to achieve the desired light deflection angles without introducing unwanted optical effects.
2Illumination intensity
If additional masking elements are added to control beam distribution, then beam intensity can be adjusted, but device complexity increases
Solution Approach 1:
The transparent block with reflective coating serves multiple functions simultaneously: it supports the reflective coating, deflects light rays to control beam distribution, and eliminates the need for separate masking elements. By integrating these functions into a single component, the patent reduces device complexity while maintaining the ability to adjust and control beam intensity and distribution patterns.
Solution Approach 2:
The patent merges the functions of the support structure and the light-deflecting element into a single integrated transparent block. Instead of having separate masking elements and support structures, the reflective coating is applied directly to the transparent block, which itself performs the light deflection function. This merging of functions reduces the number of components and simplifies the overall device architecture.
3Illumination intensity
If a transparent block with reflective coating is used to deflect light rays, then beam intensity is increased by up to 50%, but the structure becomes more complex
Solution Approach 1:
The patent achieves a 50% increase in beam intensity by optimizing key parameters of the transparent block, including its position relative to the light source and reflector, the angle of the reflective coating, and the dimensions of the block. By carefully controlling these parameters, the design maximizes light deflection efficiency and beam intensity while avoiding the need for complex additional components. The parameter optimization allows a relatively simple structure to achieve significant performance improvement.
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 solution increases the maximum intensity of the beam by up to 50% without significant loss of flux, improving the optical performance and eliminating the need for additional masking elements, thus enhancing the clarity and range of the road-type beam.
Implementation Method 1
a bender placed between the source and the dioptric element and comprising a transparent block whose upper face is provided at least partially with reflective coating. The upper face of the bender deflects upwards at least some of the rays emitted by the source and/or reflected by the reflector
Data Source
Figure 1
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Figure 3~4
AI summary
The module has a reflector (R) defining an optical axis (X), and a dioptric element i.e. convex lens (L). A light source (S) e.g. LED, is arranged between the reflector and the dioptric element. A folder (P) is placed between the light source and the dioptric element. The folder has a transparent block (B) whose upper edge is partially formed with a reflective coating (Re). The transparent block is disposed perpendicular to the optical axis with lateral walls parallel to each other, where one of the lateral walls is curved.