Single-Piece Low Beam Optics for Compact Vehicle Headlamps
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Solution Overview
Problem
Current vehicle headlamp systems for producing low beams are complex, costly, and limited in styling options due to their component count and physical dimensions.
Innovation Solution
A single-piece vehicle headlamp optics made of transparent material with specific surface portions, including an inner primary optics surface, inner shutter surface, and outer imaging lens surface, arranged to direct light efficiently without a condenser secondary lens, using plastic materials for cost-effectiveness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reflectors or projector systems are used to produce low beam, then the low beam function is achieved, but the number of components and system complexity increase
Solution Approach 1:
The patent combines multiple optical functions (collimation, imaging, beam shaping, and shuttering) into a single integrated optics component. This single piece of transparent material replaces the traditional multi-component projector system, reducing part count while maintaining the low beam function through carefully designed internal surfaces and geometries
2Reliability
If traditional projector systems are used, then low beam is produced, but manufacturing and maintenance costs increase
Solution Approach 1:
By integrating multiple optical functions into one component, the patent reduces assembly requirements and potential failure points, thereby lowering manufacturing and maintenance costs while preserving low beam production capability
3Reliability
If conventional headlamp systems are used, then low beam function is provided, but physical dimensions limit styling options
Solution Approach 1:
The consolidation of multiple optical elements into a single compact component significantly reduces the overall volume required for the headlamp assembly, providing more space flexibility for vehicle styling and design variations
4Illumination intensity
If a condenser secondary lens is included, then light control is improved, but the optics becomes more complex and larger
Solution Approach 1:
The patent extracts and eliminates the condenser secondary lens from the optical system by redesigning the light control mechanisms using only the primary optics surface and shutter arrangements, thereby simplifying the overall structure while maintaining effective light control
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
Simplifies manufacturing, reduces costs, and enhances compactness while improving light efficiency and visibility with a more intense low beam, allowing for easier installation and alignment.
Implementation Method 1
light rays entering the entrance hole and passing through the inner primary optics surface can exit the optics through the imaging lens surface
Implementation Method 2
the inner shutter surface deviates some of the light rays that would not directly hit the outer imaging lens
Implementation Method 3
light rays entering the entrance hole and passing through the inner primary optics surface can exit the optics through the imaging lens surface
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention concerns a low beam vehicle headlamp optics made of at least one piece of solid transparent material (1), the surface of which comprises : - an entrance hole (2) extended by an entrance passage (3) delimited by an inner side wall (4), - at the end of the entrance passage (3), an inner primary optics surface (5) and an inner shutter surface (6) terminated by an edge (7) and located downstream of the primary optics surface (5), - an outer curved collimator surface (8) surrounding the entrance passage (3), - an outer imaging lens surface (9) opposite the entrance hole (2). The inner primary optics surface (5), the inner shutter surface (6) and the imaging lens surface (9) are arranged relative to each other so that light rays entering the entrance hole (2) and passing through the inner primary optics surface (5) can exit the optics through the imaging lens surface (9).