Vehicle Lamp Microlens Array with Variable Exit Lens Heights
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Solution Overview
Problem
The existing microlens arrays in vehicle headlamps have a limited spread angle, restricting their use to only welcome light functions and increasing costs when trying to implement other lighting functions like low beams, as more modules or tilted angles are required, which affect aesthetics and fabrication costs.
Innovation Solution
A vehicle lamp design with a microlens array module where the exit lenses have varying heights in the top-bottom direction, allowing for both concentrated light in the central area and spread light in the outer area using a single type of lens, and adjustable LED positions on PCBs to achieve desired light intensity and beam width, reducing component diversity and fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a microlens array with limited spread angle (about 15 degrees) is used, then light concentration performance is improved, but the lighting function versatility deteriorates
Solution Approach 1:
The patent applies local quality by making the lens height a variable parameter across different spatial locations. Specifically, lenses in the upper region have different heights than lenses in the lower region, allowing each region to perform different lighting functions (high beam vs. low beam) with the same microlens array structure, thereby resolving the contradiction between light concentration and lighting function versatility.
2Adaptability or versatility
If the number of MLA modules is increased to improve spread area coverage, then lighting function versatility is improved, but material cost increases excessively
Solution Approach 1:
The patent implements universality by designing a single microlens array structure that can perform multiple lighting functions (welcome light, high beam, low beam) through variable lens heights. This eliminates the need for separate MLA modules for different lighting functions, thereby reducing material costs while maintaining lighting function versatility.
3Adaptability or versatility
If tilting angles of specific MLA modules are adjusted to improve spread area coverage, then lighting function versatility is improved, but aesthetic appearance deteriorates
Solution Approach 1:
Instead of tilting the entire MLA module which would affect aesthetic appearance, the patent applies local quality by varying only the lens heights within the module while keeping the overall module structure and orientation uniform. This allows different lighting functions to be achieved without compromising the aesthetic appearance of the vehicle exterior.
4Adaptability or versatility
If different types of microlens arrays are developed for hot zone and spread areas, then lighting function versatility is improved, but development cost increases due to redundant development
Solution Approach 1:
The patent achieves universality by creating a single microlens array design with variable lens heights that can serve both hot zone and spread area requirements. This eliminates the need for separate microlens array developments for different zones, thereby reducing development costs while maintaining lighting function versatility.
5Illumination intensity
If the number of components is increased to achieve desired light intensity and beam width, then lighting performance is improved, but fabrication cost increases
Solution Approach 1:
The patent applies parameter changes by varying the lens height parameter within the microlens array to achieve different lighting functions and performance characteristics. This allows optimization of light intensity and beam width without increasing the number of components, thereby reducing fabrication costs while maintaining lighting performance.
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
Enables simultaneous light concentration and spread in vehicle headlamps, reducing development and fabrication costs by using common components across different modules and vehicles, while maintaining aesthetic appeal and improving light distribution.
Implementation Method 1
a microlens array (MLA) is a lens configuration in which a plurality of individual lenses is arrayed. The microlens array is used to spread and concentrate light
Data Source
AI summary
Provided is a vehicle lamp including a light source module. The light source module includes a light source configured to generate and emit light and a microlens array module provided in front of the light source and configured such that light enters the microlens array module. The microlens array module includes an incident lens array configured such that the light enters the incident lens array and including a plurality of incident lenses and an exit lens array provided in front of the incident lens array, configured to receive the light that has entered the incident lens array and emit the light outward, and including a plurality of exit lenses. The exit lens array is configured such that heights of the exit lenses are different in a top-bottom direction of a vehicle.