Integrally Molded Optical Unit with Light-Shielding Member
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Solution Overview
Problem
The existing optical units for vehicle lamps with multiple light sources and lenses face challenges in preventing unintended light distribution and assembly errors due to complex configurations and large numbers of parts, making assembly difficult.
Innovation Solution
An optical unit with integrally formed first lenses and a light-shielding member, which is also integrally formed by two-color molding, is used to prevent unintended light distribution by shielding light between adjacent lenses, simplifying assembly and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If partition members are provided between adjacent lenses to prevent unintended light distribution, then light distribution control is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The light-shielding member is integrated with the first lenses to form a single molded part through two-color molding. This merging eliminates the need for separate partition members between adjacent lenses, reducing device complexity while maintaining the function of preventing unintended light distribution. The integrated structure allows light shielding to be achieved without adding separate components that would increase assembly difficulty.
Solution Approach 2:
The first lenses serve dual functions: they condense light from their corresponding light sources to form light source images, and they provide light shielding to adjacent lenses through the integrated light-shielding member. This multi-functionality eliminates the need for separate partition members, reducing the number of parts while maintaining effective light distribution control.
2Object-generated harmful factors
If partition members are provided between adjacent lenses to prevent unintended light distribution, then light distribution control is improved, but assembly work becomes more difficult
Solution Approach 1:
By integrating the light-shielding member with the first lenses into a single molded part, the number of components requiring assembly is reduced. The two-color molding process creates a unified structure that eliminates the need to separately install partition members, thereby simplifying assembly work and reducing assembly time.
Solution Approach 2:
The integrated structure of the first lenses and light-shielding member allows the lens assembly to be self-contained and pre-assembled as a single unit. This self-service approach eliminates the need for complex multi-step assembly operations involving separate partition members, making the overall assembly process simpler and more efficient.
3Object-generated harmful factors
If partition members are provided between adjacent lenses to prevent unintended light distribution, then light distribution control is improved, but the number of parts increases
Solution Approach 1:
The light-shielding member is merged with the first lenses to form a single integrated component through two-color molding. This merging reduces the total number of parts by eliminating separate partition members that would otherwise be required to prevent unintended light distribution between adjacent lenses.
Solution Approach 2:
The first lenses perform multiple functions: light condensation for their own light sources and light shielding for adjacent lenses. This multi-functionality reduces the need for additional parts, as the same component structure serves both optical functions without requiring separate partition members.
4Ease of manufacture
If lenses are assembled separately from light-shielding members, then manufacturing flexibility is improved, but assembly error increases
Solution Approach 1:
By integrating the light-shielding member with the first lenses into a single molded part, the patent eliminates the need for separate assembly operations. The two-color molding process creates a unified structure where the relative positions of lenses and light-shielding members are fixed during manufacturing, thereby reducing assembly errors while maintaining manufacturing flexibility through integral formation.
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 effectively prevents unintended light distribution and reduces assembly errors by integrating the light-shielding member with the lenses, enhancing manufacturing efficiency and reducing the complexity of assembly work.
Implementation Method 1
condensing light from the corresponding light sources, and forming corresponding light source images
Implementation Method 2
shielding light passing through one first lens so as not to enter the other first lens
Data Source
AI summary
Provided is an optical unit capable of preventing unintended light distribution and having a small assembly error while using a plurality of light sources and a plurality of lenses. An optical unit (10) includes: a plurality of light sources (26); a plurality of first lenses (30) integrally formed, respectively arranged to correspond to each of the light sources (26), condensing light from the corresponding light sources (26), and forming corresponding light source images on a predetermined virtual plane; a second lens (12) projecting projected images of the light source images forward; and a light-shielding member (31) extending between two adjacent first lenses (30) in the first lenses (30), and shielding light passing through one first lens (30) so as not to enter the other first lens (30), in which the light-shielding member (31) and the first lenses (30) are integrally formed by two-color molding.