Segmented Lens Direct Headlamp Module for Compact Light Control
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Solution Overview
Problem
Current vehicle headlamp modules with reflective surfaces are bulky, costly, and have low light efficiency due to the complexity of internal components and excessive parts in the optical path.
Innovation Solution
A direct-type vehicle headlamp module featuring a radiator, LED chip, and a lens with a unique outer surface divided into three areas with different curved shapes, allowing direct light emission and control of light transmission without a reflective surface, enhancing brightness and beam distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a reflective surface and poly ellipsoid system module are used, then light shape can be broadened, but the structure becomes large and broad, affecting vehicle lamp appearance
Solution Approach 1:
The lens outer surface is segmented into three functional areas with different curved surface shapes: a first area for forming cut-off line shape, a second area for increasing central brightness, and a third area for broadening light shape. This segmentation allows each region to perform its specific function independently, achieving comprehensive light control in a compact overall structure.
Solution Approach 2:
Different regions of the lens outer surface are given different local qualities through varying curved surface shapes. The first area has a shape optimized for cut-off line formation, the second area for brightness enhancement, and the third area for light shape broadening. This local quality differentiation enables precise control of light distribution across different spatial zones.
2Shape
If multiple internal components (reflective surface, light-shielding plate, lens) are used, then light can be shaped and directed, but light efficiency decreases due to energy loss through multiple interfaces
Solution Approach 1:
The invention extracts and eliminates the reflective surface and light-shielding plate from the traditional multi-component system, retaining only the essential lens component. By removing these intermediate components, the optical path is simplified to a direct transmission path from LED chip through the lens, eliminating energy losses at multiple interfaces while maintaining light shaping capability through the segmented lens design.
Solution Approach 2:
Multiple functions previously performed by separate components (light shaping, brightness control, cut-off line formation) are merged into a single integrated lens structure. The segmented lens combines all these functions in one component, reducing the number of optical interfaces and eliminating energy losses associated with multiple component interactions.
3Ease of operation
If a traditional headlamp module with multiple components is used, then light can be controlled, but the number of parts increases, increasing manufacturing complexity and cost
Solution Approach 1:
The invention merges multiple light control functions into a single lens component with segmented outer surfaces. The three different curved surface areas on the lens collectively perform all necessary light control operations (cut-off line formation, brightness enhancement, light shape broadening), eliminating the need for separate reflective surfaces, light-shielding plates, and other intermediate components.
Solution Approach 2:
The single lens component achieves multi-functionality by incorporating three different curved surface shapes on its outer surface. Each shape performs a specific function, but all functions are integrated into one universal component that replaces the traditional multi-component system, simplifying the overall device structure while maintaining comprehensive light control capability.
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 design results in a compact, efficient, and cost-effective headlamp module with improved light efficiency and reduced optical energy loss, overcoming the limitations of prior art by eliminating unnecessary components in the optical path.
Implementation Method 1
a curved surface shape corresponding to a first area is configured to form a cut-off line shape, a curved surface shape corresponding to a second area is configured to increase brightness of a central area of a light shape, and a curved surface shape corresponding to a third area is configured to broaden the light shape
Data Source
AI summary
A direct-type vehicle headlamp module, including a radiator, a light-emitting diode (LED) chip, and a lens, the radiator and the lens are fixed to form an accommodating cavity for accommodating the LED chip, the LED chip is fixed on the radiator, a light ray emitted by the LED chip is directly emitted through the lens, an outer surface of the lens is divided into three areas, curved surface shapes of outer surfaces of the areas are different from each other, a curved surface shape corresponding to a first area is configured to form a cut-off line shape, a curved surface shape corresponding to a second area is configured to increase brightness of a central area of a light shape, and a curved surface shape corresponding to a third area is configured to broaden the light shape. Transmission and emergence directions of the light ray having different curved surface shapes to form the cut-off line shape.