Segmented Holder for Precise Collimator Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing lighting arrangements face challenges in precisely positioning optical elements relative to light sources, which affects the resulting beam quality, particularly in adaptive driving beam applications.

Innovation Solution

A lighting arrangement with a holder comprising separate portions and spaced openings to securely and precisely position collimator elements relative to light sources, allowing for exact alignment and minimal light loss, using a two-piece holder design that assembles around the collimator elements to facilitate easy manufacturing and secure positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional holding methods are used for collimator elements, then the device complexity is reduced, but the positioning precision and beam quality deteriorate

Engineering Contradiction:

Improvepositioning precision of collimator elementsVSAvoidholder structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The holder is divided into a first portion and a second portion that are separate from each other. The collimator elements are positioned between these two portions, allowing for precise positioning while maintaining a relatively simple overall structure. Each portion can be manufactured independently and then assembled, reducing manufacturing complexity while achieving high positioning precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holder acts as an intermediary structure between the light sources and the collimator elements. By introducing this intermediate holding mechanism with multiple portions, the patent achieves precise positioning of collimator elements without requiring direct complex integration, thus resolving the contradiction between positioning precision and device complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If a single-piece holder design is used, then the manufacturing process is simpler, but the positioning accuracy and alignment of collimator elements deteriorate

Engineering Contradiction:

Improvealignment accuracy of collimator elementsVSAvoidholder manufacturing ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The holder is segmented into multiple portions that can be manufactured separately using standard manufacturing processes. This segmentation allows each portion to be optimized for its specific function while maintaining ease of manufacture. The separate portions are then assembled to achieve the required alignment accuracy, resolving the contradiction between manufacturing ease and positioning accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The collimator elements are positioned and aligned during the assembly process of the multiple holder portions, rather than requiring complex precision machining of a single-piece holder. This preliminary positioning action during assembly achieves high alignment accuracy while keeping the manufacturing process of individual portions relatively simple.

Inventive Principle:

Principle #10Preliminary action

3Illumination intensity

If collimator elements are positioned closer to light sources, then beam control is improved, but light loss increases due to improper positioning

Engineering Contradiction:

Improvebeam quality and intensity distributionVSAvoidlight loss

Core Design Contradiction:

Illumination intensityVSLoss of energy

Solution Approach 1:

The patent replaces mechanical adjustment mechanisms with a precisely engineered holder structure that provides fixed, accurate positioning of collimator elements relative to light sources. This substitution achieves optimal beam control and minimizes light loss through precise geometric positioning rather than mechanical adjustment, resolving the contradiction between beam quality and light loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 positioning of collimator elements, ensuring optimal beam control and reduced light loss, thereby improving the intensity distribution and beam quality in lighting applications such as automotive headlamps.

Implementation Method 1

A plurality of collimator elements 18, 18', 18'' extending in the direction of an optical axis X are arranged in parallel in spaced arrangement. Each collimator element 18, 18', 18'' is shaped to widen with increasing distance from the light source 22

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

The intensity distribution of light emitted from such a lighting arrangement may be modified by controlled operation of the individual light sources

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentEP3959468B1Holding collimator elements in a lighting arrangement

Publication Date: 2023.12.27 LUMILEDS LLC

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

A lighting arrangement (10) includes a plurality of light sources (22) in spaced arrangement. Collimator elements (18) are arranged in front of the light sources (22). A holder with a plurality of spaced openings (36) is provided to hold the collimator elements (18) within the openings (36) in such a way that said openings (36) are arranged to contact said collimator elements (18) from at least two opposed sides, In order to allow exact positioning and easy manufacturing, the holder (14) comprises at least a first portion (14a) and a second portion (14b), such that at least some of the openings (36) are formed between the first and the second portions (14a), (14b).