Vehicle Lighting Lens Cutoff-Line Segmentation for Resin Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle lighting appliance lenses and units face challenges in achieving smooth resin flowability and precise control of low-beam light distribution patterns, particularly in preventing warping of cutoff lines.
Innovation Solution
A vehicle lighting appliance lens with an incidence part, a reflective surface based on a paraboloid of revolution, a cutoff-line forming part disposed in the left-right direction, and an emission surface, where the reflective-surface focal point is near the cutoff-line forming part, and the reflective surface has central and outer regions with tilted reflective-surface optical axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the contour curve of the end surface of the cutoff-line forming structure is formed with an arc shape, then the aesthetic appearance is improved, but the resin flowability at the end face deteriorates
Solution Approach 1:
The cutoff-line forming structure is divided into two distinct functional regions: an arc-shaped end surface portion that contacts the lens to define the cutoff line geometry, and a planar side surface portion that provides a smooth surface for resin flow during molding. This segmentation allows each region to optimize its function without compromising the other.
Solution Approach 2:
Different surface geometries are applied to different portions of the cutoff-line forming structure: the end surface has an arc shape to define the cutoff line, while the side surface has a planar shape to ensure resin flowability. This local differentiation of surface quality resolves the contradiction between aesthetic appearance and manufacturing ease.
2Ease of manufacture
If the light shielding part is formed with a simplified linear shape extending in the left-right direction, then the resin flowability is improved, but the control precision of the low-beam light distribution pattern deteriorates
Solution Approach 1:
The reflective surface is segmented into multiple regions (first, second, third, and fourth reflective regions) with different optical functions. The first and second regions control light for the left cutoff line, while the third and fourth regions control light for the right cutoff line. This segmentation enables precise control of the light distribution pattern while maintaining a simplified overall structure.
Solution Approach 2:
Different portions of the reflective surface are assigned different functions: some regions are optimized for reflecting light to form the left cutoff line, while other regions are optimized for the right cutoff line. This local functional differentiation achieves precise light distribution control without requiring a complex overall structure.
3Device complexity
If the light shielding part is formed with a simplified linear shape, then the manufacturing process is simplified, but the cutoff line warps upward when shifting from the middle to the left and right
Solution Approach 1:
The reflective surface is divided into multiple reflective regions with specific geometric configurations. Each region is designed to reflect light at specific angles to ensure that the cutoff lines remain horizontal and do not warp when viewed from different positions. This segmentation maintains structural simplicity while achieving precise optical control.
Solution Approach 2:
The reflective surface employs asymmetric positioning and configuration of reflective regions to compensate for optical distortions. By strategically placing reflective regions at different positions and angles, the design ensures that light paths from the light source are properly directed to form straight, non-warped cutoff lines across the entire field of view.
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 improves resin flowability, enhances control over low-beam light distribution patterns, and prevents warping of cutoff lines, ensuring compliance with regulatory standards.
Implementation Method 1
a reflective surface that has a reflective-surface focal point and reflects incident light from the incidence part
Implementation Method 2
a reflective surface based on a paraboloid of revolution, has a reflective-surface focal point that is a focal point of the paraboloid of revolution
Data Source
AI summary
A vehicle lighting appliance lens, a vehicle lighting appliance unit, and a vehicle lighting appliance device each includes an incidence part, a second reflective surface, a cutoff-line forming part, and an emission surface. The cutoff-line forming part is provided in the left-right direction of a vehicle. As a result, the flowability of resin is improved, the control of a low-beam light distribution pattern is improved, and a cutoff line without warping is formed.