Segmented Projection Lens Layout for Inclined Vehicle Lamp Substrates
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Solution Overview
Problem
Existing vehicle lamps struggle to form a clear horizontally-long light distribution pattern when the substrate is arranged in a left-right direction due to space limitations on the vehicle body, leading to improper positioning of light emitting elements relative to the projection lens.
Innovation Solution
The vehicle lamp is configured with a projection lens divided into first and second lens regions, where the focal length of the second lens region is set to a value greater than the first, allowing light emitting elements to be arranged in an inclined position while maintaining an appropriate positional relationship with the back focal point, and a light shielding member is used to control light direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a lamp lens is designed with a complex curvature to redirect light from an LED module positioned above the optical axis, then the light distribution and illumination quality are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The lamp lens is divided into multiple segments or zones, each with different curvature radii. The first region has a first curvature radius and the second region has a second curvature radius, allowing the lens to be manufactured in sections rather than as a single complex piece, thereby reducing manufacturing difficulty while maintaining the desired light redistribution function.
Solution Approach 2:
Different regions of the lamp lens are assigned different optical properties through varying curvature radii. The first region and second region have distinct curvature characteristics optimized for their specific functions in light redistribution, allowing each local area to perform its designated optical task efficiently without requiring the entire lens to be overly complex.
2Illumination intensity
If the LED module is positioned above the optical axis of the bulb, then the internal lamp lens can redirect light to achieve desired distribution, but the structural complexity and alignment precision requirements increase
Solution Approach 1:
The internal lamp lens serves multiple functions: it acts as both a light redirecting element and a structural component that defines the bulb's internal geometry. By positioning the LED module above the optical axis and using the lamp lens to redirect light, the system achieves desired light distribution without requiring additional separate redirecting components, thereby reducing overall structural complexity.
3Ease of operation
If a conventional bulb structure with a base and separate components is used, then assembly and replacement are easy, but the overall lamp unit size increases and integration is reduced
Solution Approach 1:
The LED module and the bulb structure are merged into a single integrated unit. The LED module is positioned within the bulb housing and optically coupled to the lamp lens, eliminating the need for separate base assemblies and reducing the overall lamp unit size while maintaining ease of installation and replacement as a single module.
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 enables the formation of a clear, horizontally-long light distribution pattern with uniform brightness and reduced glare, accommodating vehicle body constraints while maintaining design aesthetics and functionality.
Implementation Method 1
a first lens (310) redirects the light in a first direction, while a second lens (320) redirects the light in a second direction
Data Source
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AI summary
In a vehicle lamp configured to emit light from a plurality of light emitting elements to a lamp front via a projection lens, a horizontally-long light distribution pattern can be formed as a clear light distribution pattern even in a case where a substrate is inclined in a left-right direction with respect to a vertical plane perpendicular to a lamp front-back direction. A projection lens (40) is divided into a first lens region (40A) for controlling direct light from six first light emitting elements (30A) located closer to a front end portion of a substrate (50) and a second lens region (40B) for controlling direct light from six second light emitting elements (30B) located closer to a back end portion of the substrate (50), and a focal length of the second lens region (40B) is set to a value greater than a focal length of the first lens region (40A). With this configuration, the six first light emitting elements (30A) and the six second light emitting elements (30B) can be arranged in an appropriate positional relationship with respect to a back focal point (F 1) of the first lens region (40A) and a back focal point (F2) of the second lens region (40B).