Single PCB Head Lamp Module with Unified Optical Device
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current head lamp modules for motor vehicles require multiple printed circuit boards and optical devices, increasing manufacturing costs and complexity.
Innovation Solution
A head lamp module design featuring a single printed circuit board with two groups of light sources (low and high beam LEDs) and a single optical device that guides light through geometrical light ways and air channels, reducing components and enabling adaptive beam control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple printed circuit boards and optical devices are used for different light sources, then the head lamp module can provide low beam and high beam functions, but the manufacturing cost and device complexity increase
Solution Approach 1:
The patent combines multiple light sources (low beam and high beam LEDs) onto a single printed circuit board, eliminating the need for separate boards. Additionally, a single optical device with multiple light coupling surfaces is used to guide light from all light sources, replacing what would traditionally require multiple separate optical devices. This merging approach reduces component count and manufacturing complexity while maintaining the ability to provide both low beam and high beam functions.
Solution Approach 2:
The single optical device is designed with multi-functionality, incorporating multiple light coupling surfaces that can receive and guide light from different light sources (both low beam and high beam LEDs) through a single unified component. This universal optical device replaces what would traditionally require separate optical devices for each beam type, reducing overall system complexity while maintaining versatile beam control capabilities.
2Ease of operation
If multiple printed circuit boards and optical devices are used, then each light source can be controlled independently, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple light sources onto a single printed circuit board with unified electrical connections, reducing the number of separate components that need to be manufactured and assembled. This consolidation lowers manufacturing costs while the electrical circuit design maintains the capability to independently control each light source group, achieving both cost reduction and operational flexibility.
3Device complexity
If a single optical device receives light from both light source groups, then the device complexity is reduced, but the light distribution control becomes more challenging
Solution Approach 1:
The optical device incorporates different light coupling surfaces with locally optimized properties tailored to specific light sources. Each light coupling surface is designed with specific geometric and optical characteristics suited to its corresponding light source type, enabling precise light distribution control despite the unified single-device structure. This local quality approach allows the single optical device to maintain high precision in directing different beam types.
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 lowers manufacturing costs, allows for adaptive high beam functionality, and reduces glare by independently controlling light sources, making it suitable for cost-sensitive vehicles while maintaining effective light distribution.
Implementation Method 1
The optical device comprises geometrical light ways and air channels between the light ways. Each light way may correspond to one of the light sources of the second group of light sources. The light of each of the light sources of the second group of light sources may be emitted via the corresponding light way. The emitted light may be totally reflected at the interfaces between the light ways and the air channels.
Data Source
AI summary
A head lamp module for a motor vehicle is provided, and includes one single printed circuit board, a first group of light sources, a second group of light sources, a lens and an optical device. The first group of light sources and the second group of light sources are both arranged on the printed circuit board. The first group of light sources and the second group of light sources emit light to the optical device. The optical device is adapted to guide the emitted light in a direction towards the lens. The light leaves the head lamp module through the lens.