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In the 1992 SAE Technology Convention we reported a free formed surface reflector capable of sharp-cut illumination by adding a wavy shape to a paraparaboloid reflector consisting of different horizontal and vertical parabolas. Using this reflector, it has become possible to produce headlamps having inclined lens shapes and reduced lamp heights. However, headlamps are required to look more attractive and balanced with the vehicle body design, in addition to improving their photometric performance. In the present study, we investigated new free formed surface reflectors providing higher freedom in headlamp design to meet the recent market needs.

The demand for headlamps with low profile and slant lens has been increasing in such a vehicle styling trend that it has been getting more and more aerodynamic to reduce air resistance and thereby to improve fuel consumption and driving performance. Lamp manufacturers, in answer to the demand, have tried to develop various types of new optical headlamp systems. We, Koito Manufacturing Co., Ltd., have been also studying and developing our own low profile headlamps and now we have found a new optical system which can be applied to such a severe condition of 65 mm in height and 45° of the outer lens slant. Here we report the details of the development.