Primary Lens Unit With Segmented Silicone Optics For Motor Vehicle Headlights
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Solution Overview
Problem
Existing light modules for motor vehicle headlights face challenges in precise alignment of primary optics relative to semiconductor light sources, leading to inefficiencies, thermal deformation, electrostatic charging, and potential damage from heat and outgassing, especially when using plastic components.
Innovation Solution
A primary optics unit with a holding section and light-guiding sections that utilize total internal reflection, supported by a cover plate with guide holes for precise positioning and thermal shielding, preventing contact with the carrier element and allowing for flexible and pliable silicone optics, while providing electrical grounding to prevent electrostatic discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the primary optics are positioned close to the semiconductor light source to improve light coupling efficiency, then the light capture proportion increases, but thermal deformation and electrostatic discharge risks increase
Solution Approach 1:
The primary optics is divided into multiple light-guiding sections (fiber optics sections) that can be individually positioned and aligned with semiconductor light sources. This segmentation allows precise positioning for optimal light coupling while maintaining structural flexibility to manage thermal and electrostatic stresses independently.
Solution Approach 2:
A carrier element is introduced as an intermediary component between the primary optics and the mounting structure. This carrier element provides a stable mounting platform that electrically grounds the primary optics, preventing electrostatic discharge while allowing close positioning to the light source for efficient light capture.
2Ease of manufacture
If plastic components are used in the primary optics to reduce weight and cost, then manufacturing ease improves, but thermal deformation and outgassing occur at elevated temperatures
Solution Approach 1:
The primary optics combines different materials with complementary properties: silicone rubber provides flexibility and temperature resistance for the light-guiding sections, while the carrier element uses electrically conductive material for structural stability and electrostatic grounding. This composite approach overcomes the limitations of single-material plastic components.
Solution Approach 2:
The invention changes the material parameter from conventional plastic to silicone rubber, which has superior thermal stability and flexibility. This material substitution allows the primary optics to maintain its structural integrity and optical performance at elevated temperatures without deformation or outgassing.
3Manufacturing precision
If a large number of light-guiding sections are used to achieve high spatial resolution in light distributions, then the precision of partial high beam control improves, but the design effort and alignment complexity increase
Solution Approach 1:
The primary optics is segmented into multiple independent light-guiding sections, each capable of being individually aligned with corresponding semiconductor light sources. This segmentation enables high spatial resolution light distribution control while simplifying the alignment process through modular assembly.
Solution Approach 2:
The flexible nature of the silicone rubber primary optics allows it to self-adjust and self-align with the semiconductor light sources through elastic deformation. This self-aligning property reduces the design effort and manual adjustment complexity while achieving precise alignment for high spatial resolution light distributions.
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
Enables precise alignment and efficient light coupling with reduced thermal and electrostatic risks, maintaining optical quality and enhancing the spatial resolution of light distributions, such as partial high beams, while preventing outgassing and electrostatic damage.
Implementation Method 1
The light guide section is designed in such a way that light can be guided from the light entry surface to the light exit surface with total internal reflection
Data Source
Figure 1
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Figure 4
AI summary
The optic unit (14) has a retaining portion (104) resting against a single-piece, plastic carrier element (92) to hold primary optic elements (32, 90) in the optic unit. The carrier element is formed such that light conductive portions (100) are extended between a light input surface (102) and a light exit surface (34) without contacting the carrier element. A metallic cover plate (94) comprises multiple guide holes (130). The cover plate is formed and arranged such that the light conductive portions are extended through the guide holes and supported by the guide holes.