Resin Projector Lens Gate Trace Positioning for Thermal Deformation

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Solution Overview

Problem

In projector-type headlights, resin molding projector lenses are prone to deformation and melting when used with electric discharge lamps due to infrared heat absorption, affecting light distribution patterns, and even with LED sources, deformation can alter optical characteristics.

Innovation Solution

A gate trace is formed on the circumference of the resin projector lens, positioned lower than the horizontal light axis and shifted leftward or rightward from the vertical light axis, to reduce the impact of deformation on light distribution patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a resin molding is used as the projector lens, then the lens can be manufactured with complex shapes and integrated structures, but the lens deforms or melts under infrared heat from electric discharge lamps

Engineering Contradiction:

Improvemolding capabilityVSAvoidthermal stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by positioning the gate trace specifically in the lower peripheral region of the lens, away from the optical center. This localized structural feature allows the lens to accommodate thermal deformation at non-critical areas while maintaining optical precision at the center, resolving the contradiction between molding capability and thermal stability.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The gate trace is pre-positioned during lens manufacturing to anticipate and accommodate future thermal deformation. By preparing this structural feature in advance, the lens can withstand thermal stress from electric discharge lamps without compromising optical performance, thus resolving the contradiction between ease of manufacture and reliability.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If the gate trace is positioned at the optical center, then the lens structure is symmetric and simple, but deformation at this critical position significantly affects light distribution patterns

Engineering Contradiction:

Improvestructural simplicityVSAvoidoptical alignment

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent applies asymmetry by deliberately positioning the gate trace off-center in the lower peripheral region. This asymmetric placement moves the deformation zone away from the optical axis, ensuring that even though the structure becomes slightly more complex, the critical optical alignment is preserved and light distribution patterns remain accurate.

Inventive Principle:

Principle #4Asymmetry

3Ease of manufacture

If the gate trace is positioned higher on the lens, then it is easier to manufacture and access, but deformation in this region creates more significant glare and affects the light-dark border line

Engineering Contradiction:

Improvemanufacturing accessibilityVSAvoidglare

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potentially harmful effect of gate trace deformation into a beneficial outcome by positioning it in the lower peripheral region. This location transforms what would normally be a critical defect into a non-critical feature, allowing the gate trace to be positioned for manufacturing ease while the deformation it undergoes does not create glare or affect the light-dark border line, thus eliminating harmful effects.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 configuration minimizes the influence of lens deformation on light distribution patterns, ensuring consistent illumination and compliance with standards like ECE No. 112, by redistributing heat stress and reducing glare.

Implementation Method 1

a reflector having a reflection surface to reflect a light from the light emitting device forward

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a projector lens to project the reflected light from the reflection surface forward

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 3

Because a wavelength spectrum of the electric discharge lamp, the halogen lamp, and the incandescent lamp contains a large amount of infrared elements, heat is absorbed by the projector lens

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Data Source

PatentUS8382352B2Projector-type headlight and configuration structure of resin projector lens thereof

Publication Date: 2013.02.26 STANLEY ELECTRIC CO LTD

AI summary

Disclosed is a projector-type headlight that can include a light emitting device, a reflector having a reflection surface to reflect a light from the light emitting device forward, a projector lens to project the reflected light from the reflection surface forward, the projector lens being a resin molding, and a shade to form a light distribution pattern having a light-dark border line by blocking a part of the reflected light heading from the reflection surface to the projector lens. A gate trace can be formed in a circumference portion of the projector lens. The gate trace can be provided lower than a horizontal surface on which a light axis of the projector lens passes through, and at the same time can be provided in a state of being shifted either leftward or rightward from a vertical surface on which the light axis of the projector lens passes through.