Optical Functional Unit Window Alignment via Reference Frame

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Solution Overview

Problem

Existing methods for constructing optical functional units in vehicle lighting devices struggle to precisely align windows created in opaque coatings with light sources, leading to suboptimal light distribution and potential blinding of oncoming traffic.

Innovation Solution

A method involving a frame with reference points, where the optical component is aligned and the windows are laser-cut based on detected reference points, ensuring precise alignment with the light sources in the light module.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the window is aligned in relation to reference positions on the optical component formed by grids during production, then the window alignment with the optical component is precise, but the window alignment with the light sources is inaccurate

Engineering Contradiction:

Improvewindow alignment with optical componentVSAvoidwindow alignment with light sources

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

A frame with reference points is introduced as an intermediary element between the optical component and the light sources. The frame serves as a common reference system that enables precise alignment of both components relative to each other, solving the contradiction by providing a new reference framework that connects previously misaligned elements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The frame with reference points is prepared and positioned before the final assembly of the optical component and light sources. By establishing the reference framework in advance, the alignment of subsequent components can be precisely controlled, ensuring both manufacturing precision and measurement precision are achieved.

Inventive Principle:

Principle #10Preliminary action

2Volume of moving object

If the light module size is reduced to fit smallest installation spaces, then the installation space requirement is minimized, but the tolerance deviations have more significant effect on light distribution

Engineering Contradiction:

Improvelight module sizeVSAvoidtolerance requirements

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The frame with reference points acts as a mediator that decouples the tight tolerance requirements from the miniaturized light module. By providing a stable external reference framework, small variations in light module positioning are compensated, allowing compact design without sacrificing alignment precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The reference frame is designed to compensate for potential tolerance deviations before they affect light distribution. By establishing precise reference points in advance, the system creates a buffer against positioning errors that would otherwise be magnified by the small light module size.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 method achieves precise alignment of windows with light sources, maximizing luminous flux output and minimizing light blockage by the blind edges, thereby improving light distribution and safety.

Implementation Method 1

portions of which are then removed with a laser such that at least one window is created through which the light from at least one light source can pass

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

detecting the reference points on the frame with an optical sensor

Methodology Applied

Scientific EffectOptical detection: Optical Tweezers

Data Source

PatentUS12241605B2Method for constructing an optical functional unit

Publication Date: 2025.03.04 HELLA GMBH & CO KGAA

AI summary

A method is provided for constructing an optical functional unit that has an optical component. The optical component has a surface, on which an opaque coating is applied, through which light passes. Portions of the opaque coating are removed from the surface forming at least one window through which the light from at least one light source can pass. A frame is provided that has at least two reference points. The optical component is placed on the frame. The reference points are detected on the frame with an optical sensor. The positions of the windows are calculated on the surface through which light passes in relation to the reference points with a control unit. Portions of the opaque coating are removed using a laser beam source to create the at least one window. The light module is placed in alignment with the reference points on the frame.