Vehicle Lighting Optics With Variable Microstructured Surfaces

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Solution Overview

Problem

Existing methods struggle to efficiently produce optical components with microstructured surfaces featuring differently shaped microstructure elements, particularly when varying curvatures are required, leading to difficulties in manufacturing.

Innovation Solution

The method involves forming microstructure elements with varying designs and dimensions using a limited selection of microstructure elements, which are created by laser machining on a mold surface, allowing for injection molding of optical components with specified scattering behaviors and lighting functions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If electrochemical machining process is used to create microstructured surface, then identical regularly arranged microstructure elements can be produced, but production of microstructure elements with different shapes and curvatures becomes impossible or difficult

Engineering Contradiction:

Improvemicrostructure element shape varietyVSAvoidproduction complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The microstructured surface is segmented into multiple subsections, where each subsection contains a specific arrangement of microstructure elements. This allows different regions to have different microstructure element types, shapes, and curvatures while maintaining manufacturability through standardized production processes for each subsection type.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different microstructure elements with specific shapes and curvatures are assigned to different local regions (subsections) of the optical component surface. Each subsection is optimized for its specific lighting function, creating local quality variations that achieve diverse scattering behaviors across the overall surface.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If laser machining is used to create punctiform depressions in tool insert, then microstructure elements can be formed, but all depressions must have same dimensions and different dimensions cannot be introduced

Engineering Contradiction:

Improvemicrostructure element dimension varietyVSAvoidtool insert complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The laser machining process parameters are made dynamic and variable, allowing the laser beam to create microstructure elements with different dimensions, shapes, and curvatures by adjusting focal position, pulse duration, and beam power during the machining process, rather than using fixed template depressions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The physical parameters of the laser machining process (focal depth, pulse energy, scan speed) are varied to create microstructure elements with different dimensions and shapes directly on the tool insert surface, eliminating the need for physical templates with fixed dimensions.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If multiple differently shaped microstructure elements are combined to create different lighting functions, then scattering behavior can be customized, but production complexity increases

Engineering Contradiction:

Improvelighting function varietyVSAvoidproduction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple different subsection types with various microstructure element arrangements are pre-designed and stored as digital templates. During production, the appropriate subsection design is selected and reproduced rapidly using laser machining, allowing quick switching between different lighting functions without physical retooling.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical system of physical templates and manual tooling is replaced with a digital laser machining system that can rapidly create different microstructure patterns by controlling laser parameters, enabling fast production of diverse lighting functions without mechanical reconfiguration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enables rapid and simple production of optical components with customizable scattering behaviors and lighting functions by combining differently shaped microstructure elements, facilitating the creation of various lighting functions such as taillights, brake lights, and directional indicators.

Implementation Method 1

microstructure elements... which are created by laser machining on a mold surface

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

The different microstructure elements cause a different scattering behavior, so that different scattering behaviors and thus different lighting functions

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentUS12560300B2Lighting device for vehicles and production method

Publication Date: 2026.02.24 HELLA GMBH & CO KGAA

AI summary

A lighting device for vehicles, comprising a housing containing a light source and an optical unit. The optical unit has a microstructured surface having a plurality of microstructure elements. The microstructure elements are formed from a limited selection of microstructure elements formed differently in at least two extension directions of the surface.