Vehicle Projection Lens Layout for Wide-Angle Headlamp Imaging
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Solution Overview
Problem
Existing vehicle projection lenses fail to meet light pattern requirements for vehicle headlamps, lack wide viewing angles, and are costly to manufacture while maintaining high imaging quality.
Innovation Solution
A vehicle projection lens design comprising an aspheric first lens, a cemented spherical second and third lens, and a spherical fourth lens, with an aperture stop between the third and fourth lens, achieving an F-number ≤ 0.86, a full field of view of 30 to 70 degrees, and an effective focal length of 13 to 28 mm, using plastic and glass lenses to reduce manufacturing costs and enhance optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional projection lenses are used, then manufacturing costs are reduced, but optical quality and light pattern compliance deteriorate
Solution Approach 1:
The projection lens is divided into multiple lens elements (first through fourth lenses) with different functions. The first lens handles wide-angle correction, the second and third lenses form a cemented doublet for chromatic aberration correction, and the fourth lens provides final focusing. This segmentation allows each element to be optimized for its specific function while using cost-effective materials like plastic for the first lens and glass for others.
Solution Approach 2:
The patent employs composite material construction by combining plastic and glass lenses in a single optical system. The first lens uses plastic material for cost-effectiveness and ease of molding complex aspheric surfaces, while the second, third, and fourth lenses use glass materials for superior optical properties and chromatic aberration correction. This composite approach balances manufacturing cost with optical quality.
2Device complexity
If conventional projection lenses are used, then device complexity is reduced, but viewing angle and aperture performance deteriorate
Solution Approach 1:
The first lens features an aspheric surface design with specific curvature variations to correct spherical aberration and expand the effective viewing angle. The aspheric profile allows light rays at different angles to focus properly, achieving a wide full field of view of 30-70 degrees while maintaining image quality across the entire angular range.
Solution Approach 2:
The projection lens system is designed to perform multiple functions simultaneously: it provides wide-angle viewing (30-70 degrees), achieves low F-number (≤0.86) for large effective aperture, corrects chromatic and spherical aberrations, and produces compliant light patterns for vehicle headlamps. This multi-functionality is achieved through the coordinated design of all four lens elements working together.
3Manufacturing precision
If more lens elements are added, then image quality is improved, but manufacturing cost increases
Solution Approach 1:
The second and third lenses are merged into a single cemented doublet structure, where the two lens elements are optically bonded together. This merging reduces the number of separate components, simplifies alignment and assembly, and eliminates the need for additional mounting hardware, thereby reducing manufacturing cost while maintaining the chromatic aberration correction benefits of having two different glass types.
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 design offers wide viewing angles, larger effective apertures, lower manufacturing costs, and higher image quality, while complying with government regulations regarding light pattern requirements.
Implementation Method 1
an aspheric first lens with a positive refractive power
Implementation Method 2
a cemented lens comprised of a spherical second lens and a spherical third lens. The second lens is a concave lens and has a negative refractive power, and the third lens has a positive refractive power
Implementation Method 3
a spherical fourth lens with a positive refractive power
Data Source
AI summary
A vehicle projection lens includes an aspheric first lens with a positive refractive power, a cemented lens comprised of a spherical second lens and a spherical third lens, and a spherical fourth lens with a positive refractive power arranged in order from a magnified side to a minified side. The vehicle projection lens satisfies the following conditions: (1) an aperture stop is disposed between the third lens and the fourth lens; (2) an F-number of the vehicle projection lens is less than or equal to 0.86; (3) a full field of view of the vehicle projection lens ranges from 30 to 70 degrees; and (4) an effective focal length of the vehicle projection lens ranges from 13 mm to 28 mm.