Segmented Vehicle Lamp Optics for Thermal Expansion Control
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Solution Overview
Problem
Thermal expansion of polymer-based optical elements in vehicle lamps, such as headlight modules, causes distortion in illumination patterns due to the proximity of light sources, limiting the development of more complex optical designs.
Innovation Solution
A vehicle lamp design featuring a primary optical element divided into portions separated by expansion joints, each portion aligned independently with alignment members, and held together by a lens holder, which limits the impact of thermal expansion on the overall optical function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer optical elements are used in vehicle lamps, then manufacturing ease and weight are improved, but thermal expansion causes illumination pattern distortion
Solution Approach 1:
The primary optical element is divided into multiple portions (first portion, second portion, third portion) that are separated by expansion joints. This segmentation allows each portion to expand independently when heated, preventing the distortion of the overall illumination pattern while maintaining the benefits of polymer materials.
2Device complexity
If the primary optical element is made as a single piece, then structural simplicity is improved, but thermal expansion affects the entire element uniformly causing distortion
Solution Approach 1:
The optical element is segmented into multiple portions connected by expansion joints. This allows the structure to remain relatively simple while enabling differential thermal expansion between portions, thus maintaining optical function stability despite temperature changes.
Solution Approach 2:
Different portions of the optical element are designed with different thermal expansion characteristics through the expansion joints. This local differentiation allows specific areas to expand or contract independently, preserving the overall optical performance while accommodating thermal effects.
3Adaptability or versatility
If complex optical elements are developed to improve design and energy efficiency, then performance is improved, but thermal expansion makes development more difficult
Solution Approach 1:
Complex optical elements are divided into multiple portions with expansion joints between them. This segmentation enables the development of sophisticated optical designs while mitigating the challenges posed by thermal expansion, as each portion can expand independently without affecting the overall complex structure.
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 solution reduces thermal deformation of the optical elements, maintaining consistent illumination patterns despite temperature changes, allowing for more complex and versatile lamp designs with improved assembly efficiency and reduced component costs.
Implementation Method 1
The optical element thus thermally expands, and the illumination pattern provided by the lamp is slightly distorted by this expansion.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Vehicle lamp (1) and a headlight (23) which comprises the lamp (1). The lamp (1) comprises a light source (2), a primary optical element (3), a lens holder (4), and a secondary optical element (5). The primary optical element (3) is held between the light source (2) and the lens holder (4), and it contains at least two portions (6). Adjacent portions (6) are separated from each other by expansion joints (7) for limiting effects of thermal expansion of the adjacent portions (6) on each other. Each portion (6) comprises at least one alignment member for individual alignment of the portion (6) with respect to at least one other part of the lamp (1). Both optical elements can be segmented.