Vehicle lamp and reflector

Abstract

The invention provides a vehicle lamp and a reflector. A vehicle lamp includes at least a light source, a primary reflector, and an inner lens. A method of forming a vehicle lamp includes dividing a facet region of a primary reflector into a plurality of smaller facets and analyzing light intensity performance of each smaller facet. The method further includes comparing the light intensity performance of each smaller facet to predetermined criteria and identifying smaller facets that do not meet the predetermined criteria. The method further includes adjusting a position of the light source associated with each smaller facet that does not meet the predetermined criteria, or reshaping an outer surface of the primary reflector in a region associated with each smaller facet that does not meet the predetermined criteria.

Description

Technical Field

[0001] The present disclosure relates generally to a vehicle lamp and reflector, and more particularly to a vehicle lamp and reflector that provides a desired amount of light intensity while also providing a uniform appearance. Background Art

[0002] Vehicles may include different types of lights, such as, for example, daytime running lights (DRLs) and signal lights, which are required to provide a certain amount of light intensity while also providing an aesthetically pleasing appearance. Summary of the invention

[0003] A method for forming a vehicle lamp according to an exemplary aspect of the present disclosure includes, in particular: providing a vehicle lamp that includes at least a light source, a main reflector and an inner lens, the method also including: dividing a facet area of ​​the main reflector into a plurality of smaller facets; analyzing the light intensity performance of each smaller facet; comparing the light intensity performance of each smaller facet with a predetermined standard; identifying smaller facets that do not meet the predetermined standard; and adjusting a position of a light source associated with each smaller facet that does not meet the predetermined standard, or reshaping an outer surface in an area of ​​the main reflector associated with each smaller facet that does not meet the predetermined standard.

[0004] In another non-limiting embodiment of the foregoing method, the method includes adjusting the position of the light source associated with each smaller facet that does not meet the predetermined criteria, or reshaping the outer surface of the main reflector in the area associated with each smaller facet that does not meet the predetermined criteria until each small facet meets the predetermined criteria.

[0005] In another non-limiting embodiment of any of the foregoing methods, analyzing the light intensity performance of each smaller facet also includes: positioning an illuminance sensor on the inner lens; placing an intensity sensor in a far-field position; and tracking the illuminance contribution from the light source of each smaller facet on the inner lens and tracking the luminous intensity in the far-field position.

[0006] In another non-limiting embodiment of any of the foregoing methods, before adjusting the position of the light source or reshaping the outer surface of the main reflector in an area associated with each smaller facet that does not meet a predetermined criterion, the method includes: for each identified smaller facet that does not contribute a sufficient amount of light intensity to the far-field intensity, rotating each identified smaller facet until uniform illumination is produced on the target area of ​​the inner lens.

[0007] In another non-limiting embodiment of any of the foregoing methods, the method includes adjusting a position of the light source to improve light collection efficiency if, after rotating the identified smaller facet, the identified smaller facet still does not receive sufficient light from the light source.

[0008] In another non-limiting embodiment of any of the foregoing methods, the method includes: if adjusting the position of the light source does not cause the identified smaller facet to meet the predetermined criteria, then forming a parabolic reflector for the identified smaller facet to target a designated area of ​​the inner lens.

[0009] In another non-limiting embodiment of any of the foregoing methods, each smaller facet is comprised of a plurality of cubic surfaces.

[0010] In a further non-limiting embodiment of any of the foregoing methods, the light source includes a plurality of LEDs.

[0011] In another non-limiting embodiment of any of the foregoing methods, the inner lens includes an outer-facing side having a plurality of pillow lenses and an inner-facing side facing the primary reflector.

[0012] In a further non-limiting embodiment of any of the foregoing methods, the method includes forming a textured surface on the interior-facing side.

[0013] In a further non-limiting embodiment of any of the foregoing methods, the method includes disposing an outer lens over the inner lens.

[0014] In a further non-limiting embodiment of any of the foregoing methods, the outer lens is transparent.

[0015] In another non-limiting embodiment of any of the foregoing methods, once each facet region meets predetermined criteria, a final lamp assembly including the light source, primary reflector, inner lens, and outer lens is formed.

[0016] According to another exemplary aspect of the present disclosure, a vehicle lamp includes, inter alia: a light source; a main reflector that reflects light from the light source; an inner lens that receives reflected light from the main reflector; and wherein the main reflector is divided into a plurality of facet regions, each of the plurality of facet regions having a contoured outer surface specific to each facet region to provide desired light intensity and uniform appearance.

[0017] In another non-limiting embodiment of the foregoing vehicle light, each facet region is divided into a plurality of smaller facets, and wherein the optical properties of each smaller facet within an associated facet region are used to determine a contoured outer surface specific to the associated facet region.

[0018] In another non-limiting embodiment of any of the foregoing vehicle lights, the light source includes a plurality of LEDs.

[0019] In another non-limiting embodiment of any of the foregoing vehicle lamps, the inner lens includes an outer-facing side having a plurality of pillow-type lenses and an inner-facing side facing the primary reflector.

[0020] In another non-limiting embodiment of any of the foregoing vehicle lights, an interior-facing side of the inner lens includes a textured surface.

[0021] In another non-limiting embodiment of any of the foregoing vehicle lights, the outer lens is disposed above the inner lens.

[0022] In another non-limiting embodiment of any of the foregoing vehicle lights, the outer lens is transparent.

[0023] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] According to the specific implementation, various features and advantage It will become apparent to those skilled in the art. The drawings accompanying the detailed description can be briefly described as follows:

[0025] Figure 1 A schematic perspective view of a vehicle lamp assembly according to the present disclosure is shown.

[0026] Figure 2 is similar to Figure 1 However, a view of the inner lens of the light assembly is not shown.

[0027] Figure 3 yes Figure 1 Magnified view of the main reflector and inner lens of a headlight assembly.

[0028] Figure 4 is a schematic diagram of the inward-facing surface of the inner lens.

[0029] Figure 5 is similar to Figure 4 However, the view shows a facet region divided into a plurality of smaller facets.

[0030] Figure 6 is a schematic representation of a system for analyzing the light intensity of a vehicle light assembly. DETAILED DESCRIPTION

[0031] The present disclosure details a vehicle lamp assembly, and more particularly, relates to a vehicle lamp and reflector assembly that provides a desired amount of light intensity while also providing a uniform appearance.

[0032] Vehicle lights, such as, for example, DRLs, brake lights, and tail lights, need to provide a uniform appearance and meet light illumination requirements. This becomes challenging when these lights require complex three-dimensional shapes. The complex shapes make it difficult for the optical design to produce a uniform appearance from multiple viewing angles. The present disclosure provides a unique reflector design that provides the required light intensity and uniform appearance without adding expense.

[0033] refer to Figure 1 to Figure 2 , shows a vehicle lamp assembly 10, which includes a main lens or main reflector 12, an inner lens 14, an outer lens 16, and a light source 18. In one example, the light source 18 includes one or more light emitting diode (LED) light sources; however, other types of light sources may also be used. In one example, the outer lens 16 is made of a transparent material. In one example, the inner lens 16 has a plurality of pillow lenses 22 ( Figure 3 ) and an inner facing side 24 facing the main reflector 12. In one example, the inner facing side 24 includes a textured surface 26, such as Figure 4 The pillow lens 22 and particles forming the textured surface 26 are used to diffuse light.

[0034] To create a uniform appearance, the main reflector 12 includes a Figure 5 In one example, a method of forming the vehicle light assembly 10 includes dividing the faceted region 30 of the main reflector 12 into a plurality of smaller facets 32. Figure 5 In the example shown, the facet area 30 is divided into nine smaller facets 32; however, the division may be performed with fewer or additional smaller facets. Next, the method includes analyzing the light intensity performance of each smaller facet 32, comparing the light intensity performance of each smaller facet 32 ​​with a predetermined standard, and identifying any smaller facet 32 ​​that does not meet the predetermined standard. A person skilled in the art having the benefit of this description will be able to determine the appropriate standard for the light performance requirements applicable to the vehicle lamp. In one example, the position of the light source 18 associated with each smaller facet 32 ​​that does not meet the predetermined standard is adjusted, or the outer surface of the main reflector 12 in the area associated with each smaller facet 32 ​​that does not meet the predetermined standard is reshaped. The adjustment or reshaping is used to make the identified smaller facet 32 ​​meet the desired predetermined standard.

[0035] In one example, after each reflector region 30 is cut into facets 32, an illumination sensor 34 is disposed on the inner lens 14, and an intensity sensor 36 is disposed in a far field position, such as Figure 6 The illumination contribution of each facet is then tracked on the inner lens 14 and the luminous intensity in the far field is determined. The sensor data is sent to the processing unit 38 so that the performance of each facet can be analyzed.

[0036] The processing unit 38 may include a computer having a processor, a memory, and one or more input and / or output (I / O) device interfaces communicatively coupled via a local interface. The computer includes hardware means for executing software, particularly software stored in the memory. The software in the memory may include one or more separate programs, each of which includes an ordered list of executable instructions for implementing logical functions. The software in the memory is read in whole or in part by the processor and then executed. In one example, 3D CAD is constructed using software such as Catia, far-field luminous intensity is checked using software such as LucidShape, and the appearance of the light being lit is checked using software such as Ansys SPEO.

[0037] The processing unit 38 analyzes the sensor data to identify each facet 32 ​​that does not contribute sufficient light intensity to the far field position. For each identified facet 32, the facet is rotated within its associated region to produce uniform illumination on the target area of ​​the inner lens 14. If one facet 32 ​​does not receive sufficient light from the associated light source 18, the position of the light source is adjusted to improve the light collection efficiency. If moving the light source position does not achieve the desired effect of that particular facet, a parabolic reflector and parabolic axis point are constructed to target the specified area of ​​the inner lens 14. In one example, this involves reshaping the surface area of ​​the cubic structure within the identified facet 32 ​​to provide a parabolic surface that will focus light to the specified area. The parabolic facet will then enhance the light on the inner lens 14 in that area. Once each facet area meets the predetermined criteria, the entire surface of the main reflector 12 is smoothed to provide a smooth transition between the different shapes of the outer surface contours of each facet 32, and the final lamp assembly can be formed, which includes at least the light source 18, the main reflector 12, the inner lens 14 and the outer lens 16.

[0038] By using this approach, the inner lens 14 will receive a more uniform illumination. Additionally, after the light passes through the plurality of small pillow lenses 22 and the textured surface 26 on the inner lens 14, the lamp assembly 10 will have a uniform appearance.

[0039] In one example, the parabola built into each selected facet 32 ​​will be formed to fit the facet size. As described above, the resulting reflector 12 will not be very smooth after reshaping, and a program (e.g., a CAD program) can be used to adjust the overall outer surface shape of the final reflector based on the draft angle and tool requirements. In one example, an optical software feature is used to generate small cubic prism facets to use a reflector optic to collimate the light from the light source into a beam pattern with about 5 degrees and above and below 5 degrees. These collimated lights are irradiated on an inner lens, which has a small pillow lens and a textured surface to further spread the light to meet the requirements. This area of ​​the facet is cut / divided into multiple smaller facets to analyze the performance of each facet, and the shape of the outer surface of the reflector can be adjusted within each smaller facet. By designing the reflector in this way, the headlight can meet the light requirements and have a desired uniform appearance.

[0040] The foregoing description is illustrative rather than restrictive in nature. Changes and modifications to the disclosed examples may become apparent to those skilled in the art, and the changes and modifications do not necessarily depart from the essence of the present disclosure. Therefore, the scope of protection granted to the present disclosure can only be determined by studying the attached claims.

[0041] According to the present invention, there is provided a method for forming a vehicle lamp including at least a light source, a main reflector and an inner lens, the method comprising: dividing a facet area of ​​the main reflector into a plurality of smaller facets; analyzing the light intensity performance of each smaller facet; comparing the light intensity performance of each smaller facet with a predetermined standard; identifying smaller facets that do not meet the predetermined standard; and adjusting the position of the light source associated with each smaller facet that does not meet the predetermined standard, or reshaping the outer surface of the main reflector in the area associated with each smaller facet that does not meet the predetermined standard.

[0042] In one aspect of the invention, the method includes adjusting the position of a light source associated with each smaller facet that does not meet a predetermined criterion, or reshaping the outer surface of the main reflector in an area associated with each smaller facet that does not meet the predetermined criterion until each facet meets the predetermined criterion.

[0043] In one aspect of the invention, analyzing the light intensity performance of each smaller facet also includes: positioning an illuminance sensor on the inner lens; placing an intensity sensor in a far-field position; and tracking the illuminance contribution from the light source of each smaller facet on the inner lens and tracking the luminous intensity in the far-field position.

[0044] In one aspect of the invention, before adjusting the position of the light source or reshaping the outer surface of the main reflector in the area associated with each smaller facet that does not meet a predetermined criterion, the method includes: for each identified smaller facet that does not contribute a sufficient amount of light intensity to the far-field intensity, rotating each identified smaller facet until uniform illumination is produced on the target area of ​​the inner lens.

[0045] In one aspect of the invention, the method includes adjusting the position of the light source to improve light collection efficiency if, after rotating the identified smaller facet, the identified smaller facet still does not receive sufficient light from the light source.

[0046] In one aspect of the invention, the method includes: if adjusting the position of the light source does not cause the identified smaller facet to meet the predetermined criteria, then forming a parabolic reflector for the identified smaller facet to target a designated area of ​​the inner lens.

[0047] In one aspect of the invention, each smaller facet is comprised of a plurality of cubic surfaces.

[0048] In one aspect of the invention, the light source comprises a plurality of LEDs.

[0049] In one aspect of the invention, the inner lens includes an outer-facing side having a plurality of pillow lenses and an inner-facing side facing the primary reflector.

[0050] In one aspect of the invention, the method includes forming a textured surface on the interior-facing side.

[0051] In one aspect of the invention, the method includes providing an outer lens over the inner lens.

[0052] In one aspect of the invention, the outer lens is transparent.

[0053] In one aspect of the invention, once each facet region meets predetermined criteria, a final lamp assembly including a light source, a primary reflector, an inner lens, and an outer lens is formed.

[0054] According to the present invention, a vehicle lamp is provided, which has: a light source; a main reflector, which reflects light from the light source; an inner lens, which receives the reflected light from the main reflector; and wherein the main reflector is divided into a plurality of facet regions, each of which has a contoured outer surface specific to each facet region to provide the desired light intensity and uniform appearance.

[0055] According to one embodiment, each facet region is divided into a plurality of smaller facets, and wherein the optical properties of each smaller facet within an associated facet region are used to determine a contour outer surface specific to the associated facet region.

[0056] According to one embodiment, the light source comprises a plurality of LEDs.

[0057] According to one embodiment, the inner lens comprises an outer-facing side having a plurality of pillow lenses and an inner-facing side facing the main reflector.

[0058] According to one embodiment, the inner-facing side of the inner lens comprises a textured surface.

[0059] According to one embodiment, the invention is further characterized by providing an outer lens over the inner lens.

[0060] According to one embodiment, the outer lens is transparent.

Claims

1. A method of forming a vehicle lamp comprising at least a light source, a main reflector and an inner lens, the method comprising: dividing the faceted area of ​​the primary reflector into a plurality of smaller facets; Analyze the light intensity performance of each smaller facet; comparing the light intensity performance of each smaller facet to a predetermined standard; identifying smaller facets that do not meet the predetermined criteria; as well as The position of the light source associated with each smaller facet that does not meet the predetermined criteria is adjusted, or the outer surface of the main reflector in the area associated with each smaller facet that does not meet the predetermined criteria is reshaped.

2. The method of claim 1, comprising: The position of the light source associated with each smaller facet that does not meet the predetermined criterion is adjusted, or the outer surface of the main reflector in the area associated with each smaller facet that does not meet the predetermined criterion is reshaped until each facet meets the predetermined criterion.

3. The method of claim 1 , wherein analyzing the light intensity performance of each smaller facet further comprises: placing an illumination sensor on the inner lens; placing an intensity sensor in a far field position; and tracking the illumination contribution from the light source for each smaller facet on the inner lens and tracking the luminous intensity in the far field location.

4. The method of claim 1 , wherein prior to adjusting the position of the light source or reshaping the outer surface of the main reflector in the region associated with each minor facet that does not meet the predetermined criteria, the method comprises: For each identified smaller facet that does not contribute a sufficient amount of light intensity to the far-field intensity, each identified smaller facet is rotated until uniform illumination is produced over a target area of ​​the inner lens.

5. The method of claim 4 further comprising adjusting the position of the light source to improve light collection efficiency if the identified smaller facet still does not receive sufficient light from the light source after rotating the identified smaller facet, and optionally, subsequently forming a parabolic reflector of the identified smaller facet to aim at a specified area of ​​the inner lens if adjusting the position of the light source does not cause the identified smaller facet to meet the predetermined criteria.

6. The method of claim 1, wherein each smaller facet is comprised of a plurality of cubic surfaces. The method of claim 1 , wherein the light source comprises a plurality of LEDs.

8. The method of claim 1, wherein the inner lens comprises an outer-facing side having a plurality of pillow lenses and an inner-facing side facing the primary reflector, and optionally, a textured surface is formed on the inner-facing side.

9. The method of claim 1 , comprising providing an outer lens over the inner lens, wherein the outer lens is transparent, and wherein once each facet region meets the predetermined criteria, a final lamp assembly comprising the light source, the primary reflector, the inner lens and the outer lens is formed.

10. A vehicle lamp, comprising: light source; a main reflector, the main reflector reflecting light from the light source; an inner lens, the inner lens receiving reflected light from the main reflector; as well as Wherein the primary reflector is divided into a plurality of facet regions, each of the plurality of facet regions having a contoured outer surface specific to each facet region to provide a desired light intensity and uniform appearance.

11. The vehicle lamp of claim 10, wherein each facet region is divided into a plurality of smaller facets, and wherein the optical performance of each smaller facet within an associated facet region is used to determine the contour outer surface specific to the associated facet region.

12. The vehicle lamp of claim 10, wherein the light source comprises a plurality of LEDs.

13. The vehicle lamp of claim 10, wherein the inner lens includes an outer-facing side having a plurality of pillow-type lenses and an inner-facing side facing the primary reflector.

14. The vehicle lamp of claim 13, wherein the interior-facing side of the inner lens includes a textured surface.

15. The vehicle lamp of claim 10, comprising an outer lens disposed above the inner lens, wherein the outer lens is transparent.

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