Vehicle Lighting Device Shade Segmentation
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Solution Overview
Problem
Vehicle lighting devices with semiconductor-type light sources face challenges in maintaining light distribution performance due to thermal deformation of shades caused by sunlight incidence, which requires multiple reflector designs for different countries, increasing costs and reducing efficiency.
Innovation Solution
A vehicle lighting device design where the shade is a separate, heat-resistant member independent of the first and second reflectors, allowing for common use of reflectors and reducing thermal deformation effects by using a thermally stable material like aluminum die cast for the shade.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shade is integrally formed with the first reflector and the second reflector, then the manufacturing process is simplified, but multiple types of reflectors must be provided to cope with different country specifications, increasing cost
Solution Approach 1:
The lighting device is divided into separate functional components: the reflector assembly (first reflector and second reflector) and the shade are manufactured independently. This segmentation allows the reflector to be produced as a standard component while the shade can be customized for different light distribution patterns required by various country specifications, thereby reducing the need to produce multiple types of reflectors.
Solution Approach 2:
The first reflector and second reflector are designed with universal geometry that can serve multiple light distribution patterns. By making the reflector assembly universal and independent from the shade, a single reflector design can be used across different applications while only the shade needs to be varied to meet different regulatory requirements.
2Stability of the object's composition
If the shade is integrally formed with the reflectors, then structural integration is achieved, but thermal deformation occurs when sunlight optically focuses on the shade, degrading light distribution performance
Solution Approach 1:
By separating the shade from the reflector assembly into independent components, the patent eliminates the thermal deformation problem. The shade can be positioned to receive optically focused sunlight without being thermally coupled to the reflectors, preventing heat transfer that would cause deformation and maintain consistent light distribution performance.
Solution Approach 2:
The patent introduces spatial separation and positioning structures as intermediaries between the reflector assembly and the shade. This intermediary arrangement allows the optically focused sunlight to pass through or around the shade without thermal coupling, preventing the shade from deforming while still maintaining the required light distribution pattern.
3Ease of manufacture
If the shade is made from thermoplastic synthetic resin to match the reflector material, then manufacturing consistency is maintained, but the shade deforms under thermal effects from focused sunlight
Solution Approach 1:
The patent applies different material properties to different components based on their specific functional requirements. The reflectors use thermoplastic synthetic resin for ease of molding complex curved surfaces, while the shade uses heat-resistant material to withstand optically focused sunlight. This local quality differentiation ensures each component has the optimal properties for its specific function.
Solution Approach 2:
The lighting device employs a composite material strategy where different materials are used for different components. The reflectors are made from thermoplastic synthetic resin while the shade is made from heat-resistant material, creating a multi-material system that optimizes both manufacturability and thermal 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
This configuration maintains compatibility with various light distribution patterns, reduces costs, and prevents degradation of light distribution performance even under thermal effects from sunlight, ensuring consistent illumination across different specifications.
Implementation Method 1
a first reflector which is arranged to cover the periphery of a semiconductor-type light source fixed to a heat sink member, for reflecting light emitted from the semiconductor-type light source so as to be oriented in a predetermined direction
Implementation Method 2
a second reflector for causing the reflected light from the first reflector to be incident thereto and then reflecting the incident light so as to be oriented forward of the lighting device
Implementation Method 3
a heat sink member, and a semiconductor-type light source fixed to the heat sink member
Data Source
Figure 1
Figure 2
AI summary
A vehicle lighting device is provided which is capable of merely changing a shade, thereby using a first reflector and a second reflector as they are, to cope with a variety of light distribution pattern specifications, and which is capable of avoiding deformation of a shade due to a thermal effect even if incidence of sunlight going back has optically focused on the shade. In a heat sink member 40, there are arranged: a semiconductor-type light source 10; a first reflector 21 covering the semiconductor-type light source 10 therewith; a second reflector 22 for causing the reflected light from the first reflector 21 so as to be made incident thereto and then reflecting the incident light forward of the lighting device; and a shade 30 for shading a part of the reflected light from the first reflector 21 so as to be made incident to the second reflector 22. The shade 30 is configured as another member independent of the first and second reflectors 21, 22, and is arranged in the heat sink 40.