Vehicle headlight assembly with PCB mounted shield

Abstract

The present invention relates to a vehicle headlight assembly having a PCB mounted shield. A lighting assembly for a vehicle headlight includes: a printed circuit board (PCB) defining a surface; a plurality of discrete LED devices disposed on a surface of the PCB, and each discrete LED device defining an output surface, the output surfaces together defining a layout arrangement having substantially continuous illumination; a shield directly attached to the PCB and covering an output surface of at least one of the plurality of discrete LED devices, and defining at least one edge of a predetermined illumination pattern; and an imaging lens assembly covering the plurality of discrete LED devices and configured to focus and direct light from the plurality of discrete LED devices to generate an illumination pattern according to a predetermined illumination pattern.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 543,840 filed on October 12, 2023 and U.S. Provisional Patent Application No. 63 / 557,015 filed on February 23, 2024, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates generally to lighting for motor vehicles. More particularly, the present disclosure relates to headlights for passenger vehicles such as cars and trucks. Background Art

[0004] Headlight assemblies for vehicles comply with regulations regarding cut-off patterns in order to illuminate the road ahead of the vehicle while also minimizing distraction to drivers of other vehicles, including oncoming vehicles and vehicles ahead traveling in the same direction as the subject vehicle. Several different headlighting regulations and standards may apply in different jurisdictions. Examples of such regulations and standards include the ECE developed by the United Nations Economic Commission for Europe, the standards developed by the U.S. Department of Transportation (DOT) for use in the United States and Canada, the China CCC certification standards, and the Society of Automotive Engineers (SAE) standards.

[0005] Adaptive driving beam (ADB) headlights and systems may provide enhanced automatic control of a vehicle's headlights, dimming the headlights in response to detecting light in the area ahead of the vehicle, such as the headlights of oncoming vehicles and / or the taillights of a leading vehicle. Summary of the invention

[0006] The present disclosure provides a lighting assembly for a vehicle headlamp. The lighting assembly includes: a printed circuit board (PCB) defining a surface; a plurality of discrete LED devices disposed on the surface of the PCB, and each discrete LED device defines an output surface, the output surfaces together defining a layout arrangement having substantially continuous illumination; a shield directly attached to the PCB and covering the output surface of at least one discrete LED device in the plurality of discrete LED devices and defining at least one edge of a predetermined illumination pattern; and an imaging lens assembly covering the plurality of discrete LED devices and configured to focus and direct light from the plurality of discrete LED devices to produce an illumination pattern according to a predetermined illumination pattern.

[0007] The present disclosure also provides a lighting assembly for a vehicle headlight. The lighting assembly includes: a plurality of discrete LED devices, each discrete LED device defining an output surface having a polygonal shape, the output surfaces together defining a layout arrangement having substantially continuous illumination and having a shape corresponding to a predetermined illumination pattern; a shield covering the output surface of at least one discrete LED device in the plurality of discrete LED devices and defining at least one edge of the predetermined illumination pattern in a contoured shape; and an imaging lens assembly covering the plurality of discrete LED devices and the shield. The imaging lens assembly is configured to focus and direct light from the plurality of discrete LED devices to produce an illumination pattern according to the predetermined illumination pattern.

[0008] These and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Further details, features and advantages of the design of the invention emerge from the following description of an embodiment example with reference to the associated drawings.

[0010] Figure 1 A schematic block diagram of a vehicle having two headlight assemblies according to one aspect of the present disclosure is shown;

[0011] Figure 2 shows a front view of an ADB light source according to one aspect of the present disclosure;

[0012] Figure 3 shows a cross-sectional side view of an imaging lens assembly of an ADB illumination assembly according to one aspect of the present disclosure;

[0013] Figure 4 shows a perspective wireframe diagram of an ADB lens assembly according to one aspect of the present disclosure;

[0014] Figure 5 shows a combined projection pattern according to one aspect of the present disclosure, which includes both an ADB illumination pattern and a foreground illumination pattern; and

[0015] Figure 6 An ADB lighting pattern including dimmed areas according to one aspect of the present disclosure is shown.

[0016] Figure 7 An ADB illumination pattern according to one aspect of the present disclosure is shown, with a top edge defining a cutoff pattern having a gradually curved shape.

[0017] FIG. 8A to FIG. 8B A second ADB light source according to one aspect of the present disclosure is shown.

[0018] Fig. 9 A perspective cross-sectional view of a second ADB light source according to one aspect of the present disclosure is shown. DETAILED DESCRIPTION

[0019] With reference to the accompanying drawings, the present invention will be described in detail in view of the following embodiments.

[0020] Figure 1 A schematic block diagram of a vehicle 10 having a lighting system 12 according to one aspect of the present disclosure is shown. The vehicle 10 may be a motor vehicle such as a passenger car or a truck. However, the headlamp assembly of the present disclosure may be applicable to other types of vehicles such as commercial trucks, buses, trains, etc. The vehicle 10 having the lighting system 12 of the present disclosure may also be referred to as an ego vehicle or a subject vehicle. The lighting system 12 includes a left headlamp assembly 20a and a right headlamp assembly 20b. Each of the headlamp assemblies 20a and 20b may be similar or identical to each other. In some embodiments, the headlamp assemblies 20a and 20b may include similar or identical internal components and different external components, such as a housing configured to be assembled within a structure on the corresponding side of the vehicle 10.

[0021] like Figure 1 As shown, each of the headlight assemblies 20a and 20b includes a low beam light lighting assembly 22 and an adaptive driving beam (ADB) lighting assembly 32. The low beam light lighting assembly 22 includes a low beam light source 24, which may also be referred to as a base light source or a foreground base light source. The low beam light lighting assembly 22 also includes a low beam lens 26 that overlies the low beam light source 24 and is used to direct light from the low beam light source to produce a foreground lighting pattern.

[0022] The low-beam lighting assemblies 22 of the two headlamp assemblies 20a, 20b work together to produce low-beam lighting according to the first predetermined lighting pattern 14. The first predetermined lighting pattern may be determined according to regulatory requirements and / or according to requirements set forth by an original equipment manufacturer (OEM). For example, Figure 1 A first predetermined lighting pattern 14 having an SAE pattern according to North American standards is shown. The ADB lighting assemblies 32 of the two headlamp assemblies 20a, 20b function together to produce high-beam illumination according to a second predetermined lighting pattern 16. The second predetermined lighting pattern 16 may be determined according to regulatory requirements and / or according to requirements set forth by an original equipment manufacturer (OEM). For example, Figure 1A second predetermined lighting pattern 16 is shown having a stepped pyramid shape that gradually becomes brighter toward a center portion thereof. Each of the first predetermined lighting pattern 14 and the second predetermined lighting pattern 16 may represent a pattern of light at a substantial distance away from the vehicle 10, which may be referred to as an infinite focus distance.

[0023] The ADB illumination assembly 32 includes a first ADB light source 34 and an ADB lens assembly 36 that covers the first ADB light source 34 and is configured to focus and direct light from the first ADB light source 34 to produce an ADB illumination pattern. The ADB lens assembly 36 may include an imaging lens assembly arranged to produce an ADB illumination pattern according to a predetermined illumination pattern generated by the ADB light source.

[0024] Each of the headlight assemblies 20a and 20b also includes a controller 40 that communicates with each of the low-beam light source 24 and the ADB light source 34. The controller 40 may also be referred to as a headlight intelligent lighting driver or a headlight intelligent LED driver. The controller 40 may be configured to control the pattern of light generated by the first ADB light source 34. In some embodiments, the controller 40 may control the operation of the low-beam light source 24. For example, the controller 40 may provide an on / off signal to a switching device to control the low-beam light source 24. Alternatively or additionally, the controller 40 may control the brightness level of the low-beam light source 24. In some embodiments, the controller 40 may control the light distribution output of the first ADB light source 34, such as a beam pattern generated by the first ADB light source 34.

[0025] The controller 40 includes a processor 42 coupled to a storage memory 44. The storage memory 44 includes an instruction storage device 46 that stores instructions, such as program code, for execution by the processor 42. The storage memory 44 also includes a data storage device 48 for holding data for use by the processor 42.

[0026] Figure 2 A front view of the first ADB light source 34 is shown. The first ADB light source 34 includes a printed circuit board (PCB) 50 defining a surface 52. The first ADB light source 34 also includes a plurality of discrete LED devices 54 disposed on the surface 52 of the PCB 50. Each of the discrete LED devices 54 defines an output surface 55 having a polygonal shape. Figure 2 The output surfaces 55 of the illustrated discrete LED devices 54 each have a square shape. However, some or all of the discrete LED devices 54 may have output surfaces 55 that are different polygonal shapes, such as triangles, rectangles, hexagons, octagons, etc.

[0027] The output surfaces 55 together define a layout arrangement 58 having substantially continuous illumination and having a shape corresponding to a predetermined illumination pattern. Figure 2 As shown, the first ADB light source 34 includes forty-eight (48) discrete LED devices 54 arranged in four (4) rows, with each row having a different number of discrete LED devices 54. The plurality of discrete LED devices 54 substantially fills the layout arrangement 58. However, the discrete LED devices 54 are spaced a small distance apart, such as 25 to 70 microns, to define gaps between adjacent ones of the output surfaces 55.

[0028] To simplify the explanation, Figure 2 Only one of the discrete LED devices 54 shown is labeled with a reference numeral. Layout arrangement 58 defines a triangular pattern wherein a top row has a number of discrete LED devices 54 arranged symmetrically about centerline CL, and wherein three additional rows are each arranged symmetrically about centerline CL and each have a progressively smaller number of discrete LED devices 54. Layout arrangement 58 includes rows having twenty-one (21), fifteen (15), nine (9), and three (3) discrete LED devices 54, respectively.

[0029] Each of the discrete LED devices 54 may be individually controllable to produce an intensity of light according to a predetermined illumination pattern. For example, the ADB lighting assembly 32 may be operated with each of the discrete LED devices 54 having a first predetermined brightness level, wherein different discrete LED devices in the discrete LED devices 54 are operated to produce light of different intensities in order to generate a second predetermined illumination pattern 16. Each of the discrete LED devices 54 may also be individually controllable to operate in a reduced intensity mode to produce a dimmed region of the illumination pattern. For example, a group of one or more of the discrete LED devices 54 may be operated in a reduced intensity mode to produce a dimmed region corresponding to the direction of an oncoming vehicle in order to reduce the intensity of light directed toward the oncoming vehicle.

[0030] The layout arrangement 58 can be inverted relative to the predetermined illumination pattern. For example, the layout arrangement 58 can include a triangular pattern having a flat top and gradually narrowing to a minimum width at the bottom row, which can be inverted by the ADB lens assembly 36 to produce a predetermined illumination pattern having a flat bottom and narrowing to a minimum width at the top.

[0031] The first ADB light source 34 also includes three LED drivers 56 mounted on the surface 52 of the PCB 50, wherein each of the LED drivers 56 is configured to supply power to sixteen (16) discrete LED devices 54. Thus, three (3) LED drivers 56 can all be used to power forty-eight (48) discrete LED devices 54.

[0032] Figure 3 A cross-sectional side view of the ADB lens assembly 36 is shown. The ADB lens assembly 36 can modify the pattern of light generated by the first ADB light source 34, such as by stretching the pattern and / or by mixing a certain amount of light between adjacent discrete LED devices in the discrete LED devices 54 to fill the portion of the illumination pattern corresponding to the gap, and thereby make the output pattern appear smooth and unaffected by the gap. However, the ADB lens assembly 36 can be configured to produce a second predetermined illumination pattern 16 having a shape substantially determined by the layout arrangement 58 of the discrete LED devices 54 on the surface 52 of the PCB 50.

[0033] like Figure 3 As shown, the ADB lens assembly 36 includes a first lens element 60 adjacent to the PCB 50. The first lens element 60 defines a first input surface 62 that receives light from the discrete LED device 54. The first lens element 60 also defines a first output surface 64 for outputting light. The ADB lens assembly 36 also includes a second lens element 70 covering the first lens element 60, wherein the first lens element 60 is disposed between the second lens element 70 and the PCB 50. The second lens element 70 defines a second input surface 72 that receives light from the first output surface 64 of the first lens element 60. The second lens element 70 also defines a second output surface 74 for outputting light. As shown, the first input surface 62 and the second input surface 72 each have a concave shape, and the first output surface 64 and the second output surface 74 each have a convex shape. However, either or both of the first lens element 60 and / or the second lens element 70 may have different shapes.

[0034] The ADB lens assembly 36 also includes a third lens element 80 covering the second lens element 70, wherein the second lens element 70 is disposed between the third lens element 80 and the first lens element 60. The third lens element 80 defines a third input surface 82 that receives light from the second output surface 74 of the second lens element 70. The third lens element 80 also defines a third output surface 84 for outputting light. As shown, the third input surface 82 and the third output surface 84 each have a convex shape. However, either or both of the third input surface 82 and the third output surface 84 may have different shapes.

[0035] In some embodiments, each of lens elements 60, 70, 80 has at least one aspherical lens surface. For example, some or all of input surfaces 62, 72, 82 and / or some or all of output surfaces 64, 74, 84 can be aspherical.

[0036] In some embodiments, at least two of the lens elements 60, 70, 80 are made of different materials, which can help reduce or prevent color separation of light passing therethrough. In some embodiments, all three lens elements 60, 70, 80 are made of different materials. For example, the first lens element 60 can be made of glass, and the second lens element 70 and the third lens element 80 can each be made of a different type of polymer material, such as polycarbonate (PC) and / or poly(methyl methacrylate) (PMMA), also known as acrylic. The glass material can enable the first lens element 60 to withstand the relatively high temperatures generated by the operation of the discrete LED device 54 and the LED driver 56. In some embodiments, the second lens element 70 can be made of polycarbonate (PC) and the third lens element 80 can be made of PMMA.

[0037] Figure 4 A perspective wireframe diagram of the ADB lens assembly 36 is shown. As shown, each of the lens elements 60, 70, 80 is truncated to define a rectangular shape facing the surface 52 of the PCB 50 when viewed from the front. The rectangular shape can provide advantages for packaging the ADB lens assembly 36 in the vehicle 10. Alternatively or additionally, the rectangular shape of the ADB lens assembly 36 can provide a particularly desired aesthetic design.

[0038] Figure 5 A combined projection pattern is shown that includes both a first ADB illumination pattern 100 and a low beam illumination pattern 102 , which may also be referred to as a foreground pattern. The first ADB illumination pattern 100 extends below the horizon to overlap the low beam illumination pattern 102 , according to one aspect of the present disclosure.

[0039] Figure 6A second ADB lighting pattern 100a is shown that includes a dimmed region 104 produced by operating two vertically adjacent discrete LED devices of the plurality of discrete LED devices 54 in a reduced intensity mode, the dimmed region 104 having a light intensity that meets the intensity threshold for low beam illumination. The dimmed region 104 is bounded on either side by transition regions 106 that gradually brighten outside of the dimmed region 104 to a light intensity that meets the intensity threshold for high beam illumination. For example, the dimmed region 104 may be expanded to a larger size by increasing the number of discrete LED devices 54 operated in the reduced intensity mode to provide a larger dimmed region 104 as an oncoming vehicle moves closer to the lighting system 12, thereby filling a larger portion of the field of view. In some embodiments, the transition region 106 may have a width of no more than 1.0 degree.

[0040] Figure 7 A third ADB illumination pattern 200 is shown according to one aspect of the present disclosure, and includes a top edge 220 defining a cutoff pattern having a contoured shape. The third ADB illumination pattern 200 may be similar or identical to the first ADB illumination pattern 100 and / or the second ADB illumination pattern 100a, except that the top edge 220 has a contoured shape that is a gradual curve, rather than the stepped pattern visible on the first ADB illumination pattern 100 and the second ADB illumination pattern 100a. The top edge 220 defines a spherical center 222 having a hemispherical or parabolic shape. The top edge 220 also defines a ramp portion 224 on either side of the spherical center 222, and has a continuous cutoff line extending upward toward the spherical center 222. It should be understood that Figure 7 The third ADB illumination pattern 200 shown above is merely an example, and the principles of the present disclosure may be used to generate illumination cutoff patterns having different sizes and / or shapes, and which may depend on a given implementation or design.

[0041] FIG. 8A to FIG. 8BA second ADB light source 234 is shown according to one aspect of the present disclosure. In addition to the features described herein, the second ADB light source 234 can be similar or identical to the first ADB light source 34. The second ADB light source 234 includes: a shield 240 that is directly attached to the surface 52 of the PCB 50 and covers the output surfaces 55 of some of the discrete LED devices 54. More specifically, the shield 240 includes a planar portion 242 that at least partially covers one or more of the discrete LED devices 54 on the bottom row corresponding to the top portion of the predetermined lighting pattern. Thus, the shield 240 is used to define the upper edge of the predetermined lighting pattern in a contour shape. The contour shape can be different from a stepped pattern, where the stepped pattern can be otherwise produced by rows with different numbers of discrete LED devices 54, and the contour shape forms the upper edge of the predetermined lighting pattern. For example, the shield 240 can be configured to define Figure 7 The third ADB illumination pattern 200 is shown in FIG.

[0042] The second ADB light source 234 includes a shield 240 configured to define a contoured upper edge in combination with a relatively small number of discrete LED devices 54. The combination can provide a lighting effect having one or more smoothly contoured edges, without the rough or jagged edges that may be produced by a relatively small number of discrete LED devices 54. The combination can provide significant cost savings compared to alternative designs that may require substantially more and / or smaller LED devices to achieve a similar contoured edge.

[0043] The shield 240 can be made of a metal such as stainless steel or aluminum, but other types of materials can be used. In some embodiments, the shield 240 can be non-reflective on either or both of the rear surface facing the discrete LED device 54 and / or the front surface facing outward away from the discrete LED device 54. In some embodiments, the shield 240 can reflect no more than 10% of the incident light. In some embodiments, the shield 240 can reflect no more than 5% of the incident light. In some embodiments, the shield 240 can have a non-reflective coating, such as paint, powder coating, and / or an anodized layer. In some embodiments, the shield 240 can be made of aluminum that is non-reflective by anodizing. In some embodiments, anodized aluminum sheets can be used to form the shield 240. For example, pre-anodized aluminum can be stamped and bent to form the shield 240. However, other techniques can be used when manufacturing the shield 240, such as applying anodizing and / or other coatings to the metal substrate before or after forming the metal to shape the shield 240.

[0044] The shield 240 is configured as a surface mount device (SMD) that is attached to the surface 52 of the PCB 50 by soldering. However, the shield 240 may have a different configuration and may be attached to the PCB 50 by other means, such as by clips or pins that pass through the PCB or engage its edge. In some embodiments, and as FIG. 8A to FIG. 8B As shown in , shield 240 includes a plurality of legs 246 extending perpendicular to planar portion 242 and configured to be connected to surface 52 of PCB 50. Legs 246 can be used to secure shield 240 in place, wherein planar portion 242 is parallel to and spaced apart from output surface 55 of at least one discrete LED device 54 covered by shield 240. Shield 240 is spaced apart from output surface 55 of at least one discrete LED device 54 by a distance of less than 1.0 millimeter. For example, planar portion 242 can be spaced apart from discrete LED device 54 by approximately 0.5 millimeter. Planar portion 242 should remain separated from discrete LED device 54 to prevent contact, which otherwise may produce vibration and premature wear. However, planar portion 242 is advantageously positioned relatively close to output surface 55 of discrete LED device 54 to clearly define top edge 220 of third ADB lighting pattern 200.

[0045] Fig. 9 A perspective cutaway view of the second ADB light source 234 is shown with lens elements 60, 70, 80 covering a plurality of discrete LED devices 54 on the PCB 50. The lens elements 60, 70, 80 may together form an imaging lens assembly, and the imaging lens assembly defines a focal plane that is substantially coplanar with the output surfaces of the plurality of discrete LED devices 54.

[0046] The systems, methods and / or processes described above and their steps can be implemented in hardware, software or any combination of hardware and software suitable for a particular application. Hardware can include general-purpose computers and / or special-purpose computing devices or specific computing devices or specific aspects or components of specific computing devices. Processing can be implemented in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable devices in combination with internal memory and / or external memory. Processing can also or alternatively be implemented in a dedicated integrated circuit, a programmable gate array, a programmable array logic or any other device or combination of devices that can be configured to process electronic signals. It will also be understood that one or more of the processes in the process can be implemented as a computer executable code that can be executed on a machine-readable medium.

[0047] Computer executable code can be created using a structured programming language such as C, an object-oriented programming language such as C++, or any other high-level or low-level programming language (including assembly language, hardware description languages, and database programming languages ​​and techniques), and the computer executable code can be stored, compiled or interpreted to run on one of the following: a heterogeneous combination of the above devices and processor architectures, or a combination of different hardware and software, or any other machine capable of executing program instructions.

[0048] Therefore, on the one hand, each of the above methods and combinations thereof can be implemented in a computer executable code that performs the steps of the method when executed on one or more computing devices. On the other hand, the method can be implemented in a system that performs its steps and can be distributed between devices in a variety of ways, or all functions can be integrated into a dedicated, independent device or other hardware. On the other hand, the device for performing the steps associated with the above-mentioned processing can include any of the above-mentioned hardware and / or software. All such permutations and combinations are intended to fall within the scope of the present disclosure.

[0049] The foregoing description is not intended to be exhaustive or to limit the present disclosure. Each element or feature of a particular embodiment is usually not limited to the particular embodiment, but, even if not specifically shown or described, each element or feature of a particular embodiment is interchangeable when applicable, and can be used in a selected embodiment. Each element or feature of a particular embodiment can also be changed in many ways. Such a change should not be considered as departing from the present disclosure, and all such modifications are intended to be included in the scope of the present disclosure.

Claims

1. A lighting assembly (20a, 20b) for a vehicle headlight, comprising: a plurality of discrete LED devices (54), each discrete LED device (54) defining an output surface (55), the output surfaces (55) together defining a layout arrangement (58) having substantially continuous illumination and having a shape corresponding to a predetermined illumination pattern; a shield (240) covering the output surface of at least one discrete LED device (54) of the plurality of discrete LED devices (54) and defining at least one edge of the predetermined illumination pattern; as well as An imaging lens assembly (36) covers the plurality of discrete LED devices (54) and the shield (240), wherein the imaging lens assembly (36) is configured to focus and direct light from the plurality of discrete LED devices (54) to produce an illumination pattern according to the predetermined illumination pattern.

2. The lighting assembly according to claim 1, wherein: Each of the discrete LED devices (54) defines an output surface (55) having a polygonal shape.

3. The lighting assembly according to claim 1, wherein: The at least one edge of the predetermined lighting pattern has a contour shape.

4. The lighting assembly of claim 1, further comprising a printed circuit board PCB (50) defining a surface (52), and wherein: The plurality of discrete LED devices (54) are disposed on the surface (52) of the PCB (50).

5. The lighting assembly according to claim 4, wherein: The shield (240) is configured as a surface mount device (SMD) attached to the surface (52) of the PCB (50) by soldering.

6. The lighting assembly of claim 4, wherein: The shield (240) includes a planar portion (242) having a flat shape, the planar portion (242) covering the plurality of discrete LED devices (54), and wherein the shield (240) includes a plurality of legs (246) extending perpendicular to the planar portion (242) and configured to be connected to the surface (52) of the PCB (50).

7. The lighting assembly of claim 1, wherein: The shielding element (240) is made of metal.

8. The lighting assembly of claim 1, wherein: The shield (240) includes a non-reflective coating.

9. The lighting assembly of claim 1, wherein: The shield (240) is spaced apart from the output surface (55) of the plurality of discrete LED devices (54).

10. The lighting assembly of claim 9, wherein: The shield (240) is spaced apart from the output surface (55) of the plurality of discrete LED devices (54) by a distance less than 1.0 millimeter.

11. The lighting assembly of claim 1, wherein: Each of the discrete LED devices (54) is individually controllable to produce an intensity of light according to the predetermined lighting pattern and to operate in a reduced intensity mode to produce dimmed regions of the lighting pattern.

12. The lighting assembly of claim 1, wherein: The imaging lens assembly (36) defines a focal plane that is substantially coplanar with the output surfaces (55) of the plurality of discrete LED devices (54).

13. The lighting assembly of claim 1, wherein: The layout arrangement (58) includes: the plurality of discrete LED devices (54) are spaced apart to define gaps between adjacent ones of the output surfaces (55), and wherein the imaging lens assembly (36) is further configured to mix light between adjacent ones of the discrete LED devices (54) to fill portions of the illumination pattern corresponding to the gaps, and thereby make the illumination pattern appear smooth and unaffected by the gaps.

14. The lighting assembly of claim 1, wherein: The layout arrangement (58) includes a plurality of rows of the plurality of discrete LED devices (54), wherein each of the rows has a different number of the discrete LED devices (54).

15. The lighting assembly of claim 1, wherein: The at least one edge comprises an upper edge of the predetermined illumination pattern, and wherein the shield (240) at least partially covers a discrete LED device (54) of the plurality of discrete LED devices (54) corresponding to the upper edge of the predetermined illumination pattern.

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