Reflector-less Single Lens Vehicle Lamp Design
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Solution Overview
Problem
Existing automotive work lights or off-road lamps face inefficiencies due to multiple lenses, which introduce optical inefficiency, weight, complexity, alignment challenges, and poor winter performance from air gaps between lenses and optical components.
Innovation Solution
A novel lamp assembly using a single lens module as both the light-modulating and outer lens, eliminating the need for a reflector and encapsulating outer lens, thus reducing parts and eliminating air gaps for improved durability and winter performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple lenses are used to modulate light into a desired beam pattern, then the beam pattern can be controlled, but optical inefficiency increases due to light reflection at each lens interface
Solution Approach 1:
The patent combines multiple separate lenses into a single integrated lens assembly. The first lens (collimating lens) and second lens (beam-shaping lens) are merged into one piece of optical glass with different zones having different optical powers, eliminating multiple lens interfaces and reducing light reflection losses while maintaining beam pattern control
Solution Approach 2:
The single lens assembly performs multiple functions that previously required separate lenses: it both collimates light from the LED and shapes the beam pattern. The lens has different optical zones that simultaneously achieve collimation and beam spreading/focusing, making one lens universal for tasks that previously needed multiple lenses
2Illumination intensity
If multiple lenses and a reflector are used to create a desired beam pattern, then the beam pattern can be controlled, but the lamp weight increases
Solution Approach 1:
The patent merges the reflector and multiple lenses into a simplified configuration. The single lens assembly replaces the combination of reflector plus multiple lenses, significantly reducing the number of components and overall lamp weight while maintaining beam pattern control through the optical design of the single lens
3Illumination intensity
If multiple lenses are used to modulate light, then the beam pattern can be controlled, but assembly complexity and alignment difficulty increase
Solution Approach 1:
The patent combines multiple separate lenses into a single integrated lens assembly, reducing the number of parts from three or more (reflector, first lens, second lens, outer lens) to just one optical component. This dramatically simplifies assembly procedures and eliminates the need for precise alignment between multiple lenses, as there is only one lens to install and position
4Reliability
If multiple lenses are used with air gaps between them, then the outer lens can seal the lamp, but winter performance deteriorates due to snow and ice buildup on the outer lens
Solution Approach 1:
The patent merges the outer sealing lens with the light-modulating lens into a single integrated component. The single lens assembly serves both optical functions (collimation and beam shaping) and sealing functions, eliminating air gaps between lenses. This integrated design allows the lens to be heated from within by LED heat, preventing snow and ice buildup on the outer surface while maintaining the sealing function
Solution Approach 2:
The patent converts the harmful heat generated by the LED (which would normally be waste heat to be dissipated) into a beneficial heating source for the outer lens. The LED heat warms the single lens assembly, melting snow and ice that accumulate on the outer surface, thus converting a harmful thermal byproduct into a useful function for winter operation
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 single lens module design enhances light transmission efficiency, reduces weight and assembly complexity, and improves winter performance by maintaining a higher outer lens temperature, effectively melting snow and ice.
Implementation Method 1
The lens module includes one or more lens units integrally formed in the light-transmitting material... Each lens unit has an emission surface and a light gathering portion... a solid light-path portion formed from the light-transmitting material and disposed between the incident surface and the emission surface
Data Source
AI summary
A lamp includes a housing, a lens module and bezel. The lens module has one or more integrally formed lens units. Each lens unit has an emission surface and a light gathering portion. The light gathering portion includes an incident surface. Each lens unit has a solid light-path portion formed from the light transmitting material and disposed between the incident and emission surfaces. The emission surface of each lens unit is a portion of the outer surface of the module. The lamp includes one or more light sources, each projecting light to the incident surface of a lens unit. The lamp excludes any reflecting structures directing light to the incident surface of a lens unit. The sealing bezel seals the lens module to the housing. When sealed, the lamp includes no other light-transmitting structures external to the outer surface of the lens module.