Staggered Reflector Zone III Lighting Module for Wide-Angle Vehicle Headlamps
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Solution Overview
Problem
Existing low-beam zone III lighting modules in vehicle headlamps have narrow left and right lighting angles, failing to meet the requirements for adaptive front-lighting systems, particularly when the vehicle turns, as they do not effectively expand the width of the zone III light shape to cover the necessary ±20 degrees range.
Innovation Solution
A low-beam zone III lighting module comprising a light source, lens, and a transparent optical element with a low-beam zone III forming mechanism, including staggered first and second reflectors on either side of the optical axis, which increases the width of the zone III light shape by altering the light transmission direction through the lens, and optionally features a cambered light emergent surface and wrinkled surfaces for diffuse reflection to adjust lighting intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional single reflector structure is used to form zone III, then the device complexity is low, but the left-right width of the zone III light pattern is narrow (about ±10 degrees) and cannot meet AFS requirements
Solution Approach 1:
The single reflector is divided into multiple segmented reflectors (first reflector, second reflector, third reflector, fourth reflector) with different orientations and focal points. Each reflector segment directs light to specific angular ranges, collectively achieving a wide ±20 degree zone III light pattern that meets AFS requirements while maintaining manageable structural complexity through modular design
Solution Approach 2:
The patent introduces spatial dimensionality by arranging reflectors at different positions and orientations around the optical axis. The first and second reflectors are positioned at different heights with different focal points, creating a three-dimensional light distribution system that expands the horizontal angular coverage of zone III beyond what a single planar reflector can achieve
2Stability of the object's composition
If the zone III light shape is kept stationary while the vehicle turns, then the lighting stability is good, but the light shape must be wide enough (±20 degrees) to cover the turning range, increasing the required optical element size
Solution Approach 1:
The zone III lighting function is segmented across multiple reflectors, each responsible for specific angular sectors. This segmentation allows the system to maintain a stationary wide-angle light pattern (±20 degrees) without requiring a single large optical element, as each smaller reflector segment contributes to the overall stable coverage area
Solution Approach 2:
Different reflector segments are optimized for different local angular ranges. The first reflector covers one angular sector, the second covers another, and so on. This local optimization allows each reflector to be of manageable size while collectively providing the required wide and stable zone III coverage area when the vehicle turns
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 significantly enlarges the width of the low-beam zone III light shape, meeting regulatory requirements and providing effective zone III lighting during vehicle turns without shifting the light shape, enhancing driver visibility and safety in various road conditions.
Implementation Method 1
The light emitted by the light source is reflected by the first reflector and then reflected by the second reflector
Implementation Method 2
part of light reflected by the secondary reflector is reflected and refracted by a condenser (which is a transparent optical element)
Implementation Method 3
a lens, and the light emitted by the light source is sequentially reflected by the first reflector and the second reflector into the transparent optical element, and then emitted through the light emergent surface of the transparent optical element and the lens
Data Source
AI summary
A low-beam zone III lighting module including a light source, lens, transparent optical element and low-beam zone III formation mechanism are herein. The light source, the formation mechanism, the optical element and the lens are sequentially arranged along a light shape formation light path. The formation mechanism includes one first mirror and one second mirror. The first mirror and the second mirror are on two sides of an optical axis of the lens, and are staggered. The light source is at a first focal point of the first mirror and a second focal point of the first mirror coincides with a first focal point of the second mirror. A second focal point of the second mirror is on a light incident face of the transparent optical element. The lens is directly in front of a light-emitting face of the transparent optical element. A headlamp and vehicle are also herein.