Plastic Lens Bracket with Metal Shield for Headlamp Solar Protection
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Solution Overview
Problem
Headlamps with plastic lens brackets face damage from solar radiation, and existing solutions either compromise the appearance or disrupt the light beam path.
Innovation Solution
A hybrid lens bracket composed of a plastic body with a metal surface element applied to its inner side, which protects the plastic from solar radiation without affecting the light beam path or appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a processed region (sand blasted, stone-blasted, or coated) is provided on the upper region of the lens to prevent solar radiation from entering, then the plastic body is protected from damage, but the rotational position of the lens must be precisely controlled during installation and the processed region is visible from outside which disrupts the appearance
Solution Approach 1:
The protective function against solar radiation is extracted from the lens and transferred to a dedicated metal surface element applied to the plastic body. This allows the lens to remain unprocessed and transparent, eliminating both the installation orientation constraint and the visual disruption caused by processed regions on the lens surface.
Solution Approach 2:
A metal surface element is introduced as an intermediary component between the solar radiation and the plastic body. This metal layer acts as a shield that blocks solar radiation while being applied only to the inner side of the plastic body, thus protecting the plastic without affecting the lens or visible appearance.
2Object-affected harmful factors
If a surface structure is provided on the inner face of the lens to scatter sunlight, then the plastic body is protected from focused solar radiation, but the surface structure disturbs the beam path of the headlamp light
Solution Approach 1:
The light scattering function is extracted from the lens inner face and relocated to a metal surface element on the plastic body. This extraction allows the lens inner face to remain smooth and optically clear for proper light beam formation, while the metal surface provides the scattering function to prevent focused solar radiation damage.
Solution Approach 2:
The metal surface element serves as an intermediary that handles the solar radiation scattering function separately from the lens. This mediator approach allows the lens to maintain its optical integrity for headlamp light while the metal surface manages the solar radiation protection through scattering.
3Object-affected harmful factors
If a complex stamp-bent anti-dazzle device is used to screen components from sunlight, then the plastic body is protected from solar radiation, but the device complexity increases and separate component disposal is required
Solution Approach 1:
The protective function against solar radiation is merged directly into the lens bracket structure through the application of a metal surface element to the plastic body. This integration eliminates the need for separate anti-dazzle devices and their complex assembly, while providing comprehensive protection to the plastic body.
Solution Approach 2:
The metal surface element provides multiple functions simultaneously: it protects the plastic body from solar radiation, can be applied to various lens bracket configurations, and does not interfere with lens installation or headlamp light beam path. This multi-functionality replaces the need for specialized complex anti-dazzle devices.
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 metal surface element effectively prevents damage from solar radiation, allowing the lens bracket to be installed without rotational restrictions and maintaining the headlamp's light beam integrity.
Implementation Method 1
the metal surface element which is designed in such a manner that the plastic body is protected from radiation incoming into the housing through the lens cover and entering through the lens
Implementation Method 2
A portion of the light rays from the sun can arrive through the lens and be focused by the lens on the plastic body of the lens bracket
Data Source
AI summary
A lens bracket for accommodating a lens in a headlamp and a headlamp having a lens bracket of this type, said headlamp being formed substantially by a housing made of a base body and a lens cover, and wherein the lens bracket is designed as a plastic body. It is inventively provided that the plastic body has a metal surface element which is designed in such a manner that the plastic body is protected from radiation incoming into the housing through the lens cover and entering through the lens.