Vehicle Lighting Device Using Segmented Micro-Optical Array
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Solution Overview
Problem
Conventional vehicle lighting devices require a large installation space and are costly due to expensive mask elements in their micro-optical arrays, which limits their compactness and efficiency.
Innovation Solution
A micro-optical array with multiple subarrays, including optics-free and prismatic elements, is used to create a predetermined light distribution by superimposing partial light distributions, allowing for a reduced overall height and homogeneous lighting while optimizing light distribution with simple optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a conventional lighting device uses multiple micro-optical arrays with mask elements to create different partial light distributions, then the light distribution can be optimized, but the installation space and overall height increase significantly
Solution Approach 1:
The micro-optical array is segmented into multiple subarrays (first subarray, second subarray, third subarray) arranged vertically, where each subarray contains micro-optical elements that generate specific partial light distributions. This segmentation allows different light distribution functions to be distributed across vertical layers, optimizing light projection while maintaining a compact overall structure with reduced height compared to conventional multi-array designs.
Solution Approach 2:
The patent transitions from a horizontal arrangement of multiple complete micro-optical arrays to a vertical stacking of subarrays within a single integrated array structure. This dimensional reorganization allows the light distribution functions to be compressed into a smaller vertical footprint while maintaining the functional separation of different light patterns, thereby reducing the overall height of the lighting device.
2Manufacturing precision
If a lighting device uses expensive mask elements in the micro-optical array to achieve precise light projection, then the light distribution quality improves, but the manufacturing cost increases
Solution Approach 1:
Different subarrays within the micro-optical array are assigned different local functions: the first subarray generates a first partial light distribution, the second subarray generates a second partial light distribution, and the third subarray generates a third partial light distribution. Each subarray's micro-optical elements are optimized for its specific function, achieving precise light projection control without requiring expensive mask elements across the entire array, thereby reducing manufacturing costs while maintaining precision.
3Length of stationary object
If a lighting device uses a single micro-optical array with multiple subarrays instead of multiple separate arrays, then the overall height is reduced, but the device complexity increases
Solution Approach 1:
Multiple subarrays that would traditionally require separate micro-optical arrays are merged into a single integrated micro-optical array structure. The first subarray, second subarray, and third subarray are vertically stacked and optically integrated within one array, sharing common support structures and mounting mechanisms. This merging reduces the number of discrete components and assembly steps, thereby reducing overall height without proportionally increasing device complexity.
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 achieves a compact lighting device with a reduced overall height of 15 mm, meeting legal requirements for homogeneous light distribution and optimizing light projection with minimal optical complexity and cost.
Implementation Method 1
an optical unit that is arranged in front of the light source unit in the primary direction of emission for generating a predetermined light distribution, wherein the optical unit has a micro-optical array with a multiplicity of micro-optical elements arranged in a matrix
Data Source
AI summary
A lighting device for vehicles having a light source unit containing a number of light sources, having an optical unit that is arranged in front of the light source unit in the primary direction of emission for generating a predetermined light distribution, wherein the optical unit has a micro-optical array with a multiplicity of micro-optical elements arranged in a matrix, wherein a first subarray of the micro-optical array is designed without optics to form a first partial light distribution with a light/dark boundary and with a luminance maximum in a region close to the light/dark boundary, in that at least a second subarray of the micro-optical array has such micro-optical elements. A second partial light distribution is formed below the first partial light distribution in the vertical direction. The light distribution is formed by superimposing the first partial light distribution and the additional partial light distribution.