Optical system for vehicle headlight and vehicle headlight

Abstract

The present invention relates to an optical system for a vehicle headlamp, the optical system comprising: at least one light source; at least one collimator positioned such that the collimator receives light from the light source; an array of lenticular lenses positioned such that the array of lenticular lenses receives the collimated light from the at least one collimator; and an irregular free-form lenticular lens array, the irregular free-form lenticular lens array being positioned such that the irregular free-form lenticular lens array receives light from the lenticular lens array, and wherein the irregular free-form lenticular lens array is positioned such that the irregular free-form lenticular lens array receives light from the lenticular lens array. The irregular free-form lenticular lens array includes an input lens having a plurality of irregularly sized input facets and an output lens having a plurality of output facets, where the irregularly sized input facets of the input lens focus light onto the center of the respective output facets of the output lens. The invention further relates to a vehicle headlamp having such an optical system.

Description

Technical Field

[0001] The invention relates to an optical system for a vehicle headlamp and a vehicle headlamp. Background Art

[0002] Every vehicle has a so-called low beam as its vehicle lighting. This beam is used to safely illuminate the roadway in the immediate area in front of the vehicle. Oncoming traffic must not be blinded by the low beam. Therefore, high requirements are placed on the light intensity and light distribution. The low beam also serves the function of ensuring that the vehicle is visible to other traffic participants in the dark.

[0003] DE 10 2018 217 215 A1 shows a low-beam headlamp for a motor vehicle using a lens array. In the lens array, different divergences prepared by the light source arrangement are used to effectively use the different divergences in the lateral direction specifically for the respective sections of the low-beam and achieve the desired radiation.

[0004] DE 10 20 20 10 2 226 A1 discloses a headlamp for a vehicle, wherein the headlamp comprises a light source, a collimating lens system, and a lens array. DE 10 20 18 21 7 213 also discloses a headlamp for a vehicle, which comprises a lens array.

[0005] Currently used cylindrical lens array systems, so-called CLA systems (CLA = Cylindrical Lens Arrays), have an optical efficiency of between 15% and 25%. Because CLA systems currently use glass collimators, these systems remain in a high-price range from a cost-technical perspective. The distance between the LED and the glass collimator is often significantly less than 0.5 mm, which can cause the glass collimator plate to become very hot. Summary of the Invention

[0006] The object of the present invention is to provide an optical system for a vehicle headlight and thus a vehicle headlight that overcomes the disadvantages of the prior art. In particular, an optical system for a vehicle headlight and a vehicle headlight should be provided that have a very high optical efficiency and are very cost-effective.

[0007] The above-mentioned object is achieved by the technical solutions of the patent claims, in particular by an optical system for a vehicle headlamp according to claim 1 and by a vehicle headlamp according to claim 16. Further advantages and details of the invention are apparent from the dependent claims, the description, and the drawings. Features and details described in conjunction with the optical system according to the invention naturally also apply in conjunction with the vehicle headlamp according to the invention, and vice versa, respectively, so that the disclosures concerning the various inventive aspects always refer to each other or can be referred to each other.

[0008] According to a first aspect of the invention, the object is achieved by an optical system for a vehicle headlamp, comprising:

[0009] at least one light source, in particular at least one LED;

[0010] at least one collimator positioned so that it receives light from a light source;

[0011] a lenticular lens array (CLA) positioned such that it receives collimated light from at least one collimator; and

[0012] an irregular freeform lenticular lens array (IFCLA), the irregular freeform lenticular lens array positioned such that it receives light from the lenticular lens array (CLA),

[0013] The irregular free-form cylindrical lens array (IFCLA) comprises:

[0014] an input lens having a plurality of irregularly sized input facets and an output lens having a plurality of output facets,

[0015] Here, the irregularly sized input facets of the input lens focus light onto the center of the corresponding output facets of the output lens.

[0016] The light from the light source (particularly an LED) is received and collimated by a collimator. The at least one collimator can be made of glass or thermoplastic. The collimator is preferably made of plastic. The distance between the at least one light source and the plastic collimator can be increased to 1 mm to 5 mm, preferably 1.5 mm to 2 mm, since the light-dark boundary is no longer adjusted at the collimator but in the irregular free-form cylindrical lens array (IFCLA). The number of collimators or collimating optical components can be between 1 and 10. The optical system preferably has three collimators. Each collimator is preferably associated with a light source, particularly an LED. On the one hand, an optical system with three collimators is cost-effective and, on the other hand, in combination with the downstream cylindrical lens array (CLA) and the irregular free-form cylindrical lens array (IFCLA), enables very good and defined roadway illumination.

[0017] The cylindrical lens array (CLA) expands the parallel light beam horizontally to achieve the corresponding illumination width.

[0018] The lenticular lens array (CLA) is arranged adjacent to the collimator, so that the lenticular lens array receives collimated light from the collimator and further directs it to the irregular free-form lenticular lens array (IFCLA) after horizontally expanding the parallel light beams. The irregular free-form lenticular lens array is arranged downstream of the lenticular lens array and is positioned so that the irregular free-form lenticular lens array receives the expanded light from the lenticular lens array.

[0019] The irregular free-form cylindrical lens array includes an input lens having a plurality of irregularly sized input facets and an output lens having a plurality of output facets. The irregularly sized input facets of the input lens focus light onto the center of the corresponding output facets of the output lens. The irregular free-form cylindrical lens array further causes vertical shaping of the light distribution. The output facets reflect the input facets into the traffic space and thus cause the individual facets to overlap on the roadway. The number of facets determines the uniformity in the vertical direction. Preferably, the irregular free-form cylindrical lens array includes an input lens having more than 11 input facets and an output lens having more than 11 output facets.

[0020] The input facets are constructed with irregular dimensions, in particular also with different dimensions. Irregular dimensions mean that the height of the input facets varies. Preferably, the height of the input facets decreases starting from a specific area of ​​the input lens. For example, at the center of the input lens, the input facet has a maximum height, and the height of the input facets decreases continuously towards the upper edge or the lower edge of the input lens. Due to these different heights of the input facets, it is particularly possible to achieve particularly good homogenization of the light passing through the input facets. The finer the steps in the height of the input facets, the better the homogenization of the light when it is coupled out at the output lens.

[0021] In contrast, advantageously, all output facets have the same height. The output lens, or the plurality of output facets of the output lens, directs the light, that is, squeezes it in the direction of the roadway, to form a light-dark boundary. The irregular and unequal facet heights of the input facets, combined with the highly regular output facets, achieve a homogenization of the light passing through the roadway, resulting in a particularly uniform illumination of the roadway. The number of input facets, their steps relative to one another, and the output facets form a light-dark boundary on the roadway. Light passing through the input facets and the output facets constructed in this manner can be superimposed in a targeted manner to homogenize the light on the roadway and precisely define the light-dark boundary on the roadway.

[0022] Such an optical system can be produced very cost-effectively while maintaining a high system efficiency. Since the optical system also does not have to have any light-blocking elements, an increase in optical efficiency, currently >60%, can be achieved.

[0023] Therefore, an optical system in which the cylindrical lens array (CLA) is configured to provide a horizontal spread of light and the irregular freeform cylindrical lens array (IFCLA) is configured to produce a horizontal light / dark boundary and a graduated vertical light distribution is particularly advantageous.

[0024] According to a preferred further development, the optical system can be provided in which the height of the input facets decreases at least regionally over the entire height of the input lens, in particular in steps of 20 mm to 60 mm. The height of the coupling lens can be varied. The height of the input lens can be varied. Preferably, the height of the input lens is between 12 mm and 16 mm, in particular 14 mm.

[0025] The entrance surfaces of the input lens are preferably divided into individual, irregular facets having a height between 0.06 mm and 0.6 mm. Since the number of facets determines the uniformity in the vertical direction, ideally there should be more than 11 input facets.

[0026] Preferred is an irregular free-form cylindrical lens array in which the input facets have a maximum height at the center of the input lens, while the height of the input facets decreases towards the upper and lower edges of the input lens. It can also be provided that the input lens has two areas in which the heights of the input facets (in particular the heights of the input facets) are constructed to be different. Thus, the height of the input facets can decrease from the lower edge of the input lens to the center of the input lens, and the height of the input facets can also decrease from the center of the input lens to the upper edge of the input lens. In such an irregular free-form cylindrical lens array, the arrangement structure of the input facets can be repeated.

[0027] Furthermore, in an irregular free-form cylindrical lens array, provision can be made for a small input facet to be arranged adjacent to a tall input facet, with the difference between two adjacent input facets decreasing from the center of the input lens toward the edge. Thus, for example, a 60µm-high input facet can be arranged next to a 600µm-high input facet in the center of the input lens, while the input facets at the upper and / or lower edges of the input lens can have the same height or approximately the same height. This distribution of the input facets of the input lens enables good homogenization of the light when it is coupled out of the irregular free-form cylindrical lens array.

[0028] Preferably, in an optical system, the input lens can be designed as a wedge. The wedge-shaped shape of the input lens, or the wedge-shaped shape of the sum of the input facets of the input lens, is advantageous for manufacturing reasons. The wedge shape of the input lens enables the focal length of the output facets to be irregular. By varying the thickness of the irregular free-form rod lens array, the output facets can be slightly defocused, and thus the hardness of the light-dark boundary can be adjusted to the respective customer specifications.

[0029] In one optical system, it can be advantageous to provide that the distance between the input lens and the output lens in the upper region is 4.2 mm to 5.0 mm, in particular 4.6 mm, and in the lower region the distance between the input lens and the output lens is 5.8 mm to 6.6 mm, in particular 6.2 mm. This can be achieved by a wedge-shaped profile of the input lens. The input lens preferably has a wedge-shaped profile such that the wide side of the lens is in the upper region of the input lens, while the sharply tapering region of the input lens is in the lower region of the input lens. A lens designed in this manner is compact in terms of installation space, yet still enables a very defined horizontal light-dark boundary on the roadway and a very effectively gradient vertical light distribution.

[0030] Particularly preferably, in an optical system it can be provided that all output facets of the output lens have the same height and that adjacent output facets of the output lens have different inclinations, at least regionally. This allows the light distribution to be controlled again in a targeted manner. This means that the inclination of the output facets can be different. This allows the light guided through the irregular free-form cylindrical lens array to be directed in a targeted manner, in particular in a targeted manner in the direction of the roadway, i.e., to be squeezed downwards. The different inclinations of the outcoupling facets make it possible to construct the light distribution on the roadway in a targeted manner. In particular, this makes it possible to achieve targeted, preferably uniform, roadway lighting with a very clear light-dark boundary at the same time. Depending on the inclination of the output facets, the light that is also guided through the irregular free-form cylindrical lens array can be emitted vertically differently from the irregular free-form cylindrical lens array.

[0031] Furthermore, in one optical system, it can be provided that the focal point of each input facet is located at the center of the correspondingly assigned output facet. This makes the system highly efficient and, on the one hand, also operable within manufacturing tolerances. The output facets image the input facets into the traffic area, thereby causing the individual facets to overlap on the roadway. Advantageously, it can be provided that the focal point of each output facet is located within the plane of the input lens, in particular within the plane of the input facets. The preferred irregular free-form cylindrical lens array has an input side (i.e., input lens) and an output side (i.e., output lens), wherein the focal point of the input lens is located at the output lens, and vice versa. At the output lens, the light is directed (i.e., squeezed) onto the roadway to form a light-dark boundary. The different facet heights of the input facets of the input lens achieve homogenization of the light. In combination with the output facets of the output lens, this achieves homogenization of the light on the roadway, meaning that the roadway appears uniformly illuminated.

[0032] In a preferred optical system, the cylindrical lens array (CLA) and the irregular free-form cylindrical lens array (IFCLA) may comprise, and particularly preferably consist of, a thermoplastic material, particularly polycarbonate. This means that the corresponding lenses of the cylindrical lens array (CLA) and the irregular free-form cylindrical lens array (IFCLA) may be constructed from a thermoplastic material, particularly polycarbonate. This material is particularly more temperature-stable than lenses made of PMMA (polymethyl methacrylate). The LED collimator unit allows significantly more light to be coupled into the cylindrical lens array (CLA) and the irregular free-form cylindrical lens array (IFCLA).

[0033] Furthermore, one optical system may provide that the output lens has an overhead marking region in the output facet, wherein a portion of the output facet is designed to direct light vertically upward to an angle between +2 and +5 degrees. The overhead marking region is preferably located in the middle, in particular the center, of the output lens. The inclination of the output facet in the overhead marking region differs from the inclination of the output facet surrounding this region.

[0034] Particularly preferably, in an optical system, it can be provided that the cylindrical lens array (CLA) has a coupling-in lens with a plurality of coupling-in facets and a coupling-out lens with a plurality of coupling-out facets, wherein the coupling-in facets together form a wavy profile, in particular, the curvature (Krümmung) of the coupling-in facets in a central region of the cylindrical lens array (CLA) is flatter than the curvature of the coupling-in facets in an outer region of the cylindrical lens array (CLA).

[0035] The outcoupling facets of the outcoupling lens have a wavy profile. Each wave has only one curvature. However, the curvature of the individual waves varies over the extended dimensions of the outcoupling facets. In the case of a strong curvature of the outcoupling facets, the incoupling facets are imaged more strongly and therefore have a small range of action. In the case of a weak curvature of the outcoupling facets, the incoupling facets are imaged less strongly and therefore have a large range of action. The curvature of the individual waves varies over the extended dimensions of the outcoupling facets. In the case of a strong curvature of the outcoupling facets, the light becomes more intense, but has a small range of action. In the case of a weak curvature of the outcoupling facets, the light becomes weaker, but has a large range of action.

[0036] The cylindrical lens array preferably has a coupling-in lens and a coupling-out lens, wherein at least the coupling-in facets of the coupling-in lens form a wavy profile. The cylindrical lens array is responsible for the horizontal expansion of the total light distribution. Preferably, the coupling-in facets (i.e., the waves of the coupling-in facets) are irregular in the central region of the coupling-in lens, i.e., have a flatter radius of curvature than the coupling-in facets at the edges of the coupling-in lens. As a result, the light is significantly less dispersed among each other and therefore forms a higher intensity in the central region. The higher intensity brings about a larger range of action of the light. The widened coupling-in facets are designed in such a way that the light distribution with its 1lx line lies between +-30° and 45°. In lighting technology, the 1lx line is used in order to be able to better compare the illumination widths of different systems. Preferably, the radius of curvature of the coupling-in facets is designed so that it produces a large volume of light in the edge region of the cylindrical lens array.

[0037] The focus of the outcoupling facet is on the incident surface of the irregular free-form cylindrical lens array, ie, on the input facet of the input lens of the irregular free-form cylindrical lens array.

[0038] Preferably, in an optical system, structural elements, in particular rods, are applied to the surfaces of the input facets of the input lens, the output facets of the output lens, and / or the coupling facets and / or coupling facets of the cylindrical lens array by vacuum plasma etching. The rods can be applied to the facets of the corresponding lenses by plasma structuring. This allows the light passing through the lenses to be better directed. The structural elements, in particular the rods, act as light conductors. As a result, the Fresnel reflection of light per lens can be significantly reduced, in particular from 4% to 1%. For example, in the case of four lenses, this means an increase in light efficiency of 4x3%, or 12%. The structural elements can further increase the efficiency of the optical system, in particular to >70%.

[0039] According to the present invention, in an optical system, the at least one light source is arranged on a plate, and spacer pins, in particular adjustable spacer pins, are provided between the at least one collimator and the plate for aligning the at least one light source relative to the at least one collimator. The spacer pins ensure a precise distance between the at least one light source, in particular an LED, and the collimator. With plastic collimators, this distance can be increased to 1.5 to 2 mm, since the light / dark boundary is no longer adjusted at the collimator but rather by the irregular free-form cylindrical lens array (IFCLA). This ensures that the plate on which the at least one light source, in particular the at least one LED, is arranged does not overheat.

[0040] According to another advantageous further development of the present invention, the positions of the cylindrical lens array (CLA) and the irregular freeform cylindrical lens array (IFCLA) in the optical system can be interchanged. This means that the irregular freeform cylindrical lens array (IFCLA) is arranged downstream of the collimator, followed only by the cylindrical lens array (CLA). This arrangement also achieves the stated objectives and offers the same advantages as described in detail for the optical system according to the first aspect of the present invention.

[0041] According to a second aspect of the invention, this object is achieved by a vehicle headlamp comprising an optical system according to the first aspect of the invention and a headlamp housing arranged downstream of the optical system. The vehicle headlamp has the same advantages as described in detail with respect to the optical system according to the first aspect of the invention.

[0042] Furthermore, the object is achieved by a vehicle, in particular a passenger car, which has two vehicle headlights according to the second aspect of the invention.

[0043] Further advantages, features and details of the present invention will become more apparent from the following detailed description of embodiments of the present invention in conjunction with the accompanying drawings. The features mentioned in the claims and the description may be essential to the present invention individually or in any combination. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The present invention will be described in more detail below with the aid of the accompanying drawings.

[0045] Figure 1 The optical system according to the invention is shown in a side view,

[0046] Figure 2 The optical system according to the invention is shown in a perspective view,

[0047] Figure 3 The optical system according to the invention is shown in a top view,

[0048] Figure 4 The cylindrical lens array of the optical system is shown,

[0049] Figure 5 shows the light distribution of light generated by the optical system,

[0050] Figure 6 The optical system according to the invention is shown in a perspective view,

[0051] Figure 7 Figure 2 shows the optical path of light passing through an array of irregular free-form cylindrical lenses.

[0052] Figure 8 An irregular free-form cylindrical lens array according to an optical system of the present invention is shown in a perspective view,

[0053] Figure 9 shows the focus of the input facet of an irregular free-form lenticular lens array at the center of the output facet,

[0054] Figure 10 shows the focus of the output facet of an irregular free-form cylindrical lens array in the plane of the input facet,

[0055] Figure 11 A perspective view showing an irregular free-form cylindrical lens array with an overhead identification area of ​​an optical system according to the present invention,

[0056] Figure 12 shows the overlapping area of ​​the individual incident facets of the irregular free-form cylindrical lens array,

[0057] Figure 13 The cylindrical lens array of the optical system is shown in a top view together with the light path, and

[0058] Figure 14 The cylindrical lens array of the optical system is shown in a side view together with the beam paths. DETAILED DESCRIPTION

[0059] In the following description of some embodiments of the present invention, the same reference numerals are used for the same technical features even in different embodiments.

[0060] Figure 1 The optical system 100 according to the present invention is shown in a side view, showing the arrangement of the light source 10, collimator 20, rod lens array CLA, and irregular free-form rod lens array IFCLA. The combination of the collimator 20, rod lens array CLA, and irregular free-form rod lens array IFCLA achieves a high optical efficiency of over 60%. The successive arrangement of the individual optical elements enables a space-saving design of the vehicle headlamp 200. The collimator 20 collimates the light from the light source 10 (particularly one or more LEDs), which enables precise control of the light by subsequent lens elements. The increased distance between the light source 10 and the collimator 20, preferably between 1.5 and 2 mm, achieves improved heat dissipation, which increases the service life and performance of the optical system 100. The combination of the rod lens array CLA for horizontal light distribution and the irregular free-form rod lens array IFCLA for vertical light distribution enables precise and adjustable illumination of the roadway. By using thermoplastics for the lens elements CLA and IFCLA, cost-effective production of the optical system 100 can be achieved without affecting the optical performance of the optical system 100. These advantages make Figure 1 The optical system 100 shown in FIG. 1 is particularly suitable for use in modern vehicle headlights 200 , which place high demands on efficiency, light quality, and cost optimization.

[0061] Figure 2 The optical system 100 according to the present invention is shown in a perspective view, illustrating the spatial arrangement of its components. This perspective view provides a better understanding of the spatial relationships between the various components of system 100. The clear separation of the individual optical elements demonstrates the modular nature of optical system 100, which allows for easy adjustment or replacement of individual components. This perspective view illustrates how light from light source 10 is directed through the various optical elements (collimator 20, CLA, and IFCLA), demonstrating efficient utilization of the generated light. The spatial arrangement of the components allows for effective heat dissipation, which benefits the durability and performance of optical system 100.

[0062] from Figure 2These advantages, which can be seen in the perspective view in , emphasize the well-thought-out design of the optical system 100 and its suitability for practical use in a modern vehicle headlamp 200 .

[0063] Figure 3 1 shows a plan view of an optical system 100 according to the invention. Three collimators 20 are provided in the optical system 100, wherein each collimator 20 is associated with a light source 10, in particular an LED.

[0064] Figure 4 A detailed view of a cylindrical lens array CLA is shown, wherein the coupling-in lens 30 has a coupling-in facet 32 ​​and the coupling-out lens 40 has a coupling-out facet 42. The coupling-in facet 32 ​​of the coupling-in lens 30 has a wave shape. That is, the coupling-in facets 32 together form a wave profile, wherein each individual wave has only one curvature. The curvature of the wave varies over the extension of the coupling-in facet 32. In the central region of the cylindrical lens array CLA, the curvature of the coupling-in facet 32 ​​is flatter than in the outer region. This variable curvature of the wave enables targeted control of the horizontal light distribution. The flatter curvature in the central region results in a higher light intensity and therefore a greater range of light in this region. The stronger curvature of the coupling-in facet 32 ​​in the outer region ensures a wider scattering of the light, which results in large-volume illumination in the edge region. This wavy design of the coupling facets 32 achieves an optimal balance between the range and width of the light distribution, which is important for optimal illumination of the roadway. The wavy shape of the coupling facets 32 significantly contributes to the efficient and precise light distribution of the entire optical system 100 and is important for the performance of the vehicle headlamp 200.

[0065] Figure 5The light distribution generated by the optical system 100 according to the present invention is shown, with the horizontal distribution range and the vertical light distribution shown as a light / dark boundary. The light / dark boundary is primarily generated by the irregular free-form cylindrical lens array IFCLA, particularly by the output lens 60, which has its output facets 62. The light / dark boundary extends horizontally and separates the brightly illuminated lower region of the light distribution from the darker upper region, preventing glare for oncoming traffic. The sharpness of the light / dark boundary can be adapted to the respective requirements by slightly defocusing the output facets 62. An overhead signage area 80 is integrated in the region of the light / dark boundary. In this region, a portion of the output facets 62 is designed to direct light vertically upwards at an angle between +2° and +5° to illuminate the traffic sign. The precise shaping of the light / dark boundary is achieved through the interaction of the irregularly sized input facets 52 of the input lens 50 and the output facets 62 of the output lens 60. This characteristic light-dark boundary is an essential feature for meeting legal requirements and makes a decisive contribution to traffic safety by enabling optimized illumination of the roadway while simultaneously avoiding glare.

[0066] Figure 6 Another perspective view of the optical system 100 according to the present invention is shown, particularly illustrating the arrangement of the light source 10 on the plate 70 and the spacer pins 72. The spacer pins 72 are arranged between the collimator 20 and the plate 70 on which the light source 10 is mounted. They serve to precisely align the light source 10 relative to the collimator 20 and ensure a specified distance between these components. The spacer pins are not adjustable but are designed to nominal dimensions during the manufacture of the injection mold so that any shrinkage does not affect the function of the collimator. The spacer pins enable fine-tuning of the distance. By using the spacer pins 72, the distance between the light source 10 and the collimator 20 can be increased to 1.5 to 2 mm, which is advantageous for plastic collimators. This increased distance contributes to improved heat dissipation, as the plate 70 with the light source 10 does not overheat. The spacer pins 72 play an important role in the correct positioning of the optical components and contribute to the efficiency and reliability of the entire optical system 100.

[0067] Figure 7 The optical path of light through the irregular free-form cylindrical lens array IFCLA is shown, wherein the focusing of the light through the input prism 52 to the center of the output prism 62 is shown. In particular, Figure 7The focal points of the input facets 52 can be seen in the figure. The focal point of each input facet 52 is located in the center of the respectively assigned output facet 62 of the output lens 60 of the IFCLA. This precise positioning of the focal point enables efficient and targeted light deflection by the IFCLA. The focal points of the input facets 52 enable an optimized superposition of the individual light beams on the roadway, which results in uniform illumination. Due to the different sizes of the input facets 52, the distances between the focal points vary slightly, which helps to produce the desired light distribution. The positioning of the focal point in the center of the output facet 62 helps to form the light-dark boundary and enables precise control of the vertical light distribution. This arrangement of the focal points makes the optical system 100 robust with respect to manufacturing tolerances, since small deviations in the positioning of the facets 52, 62 can be compensated.

[0068] Figure 8 A perspective view of an irregular free-form cylindrical lens array (IFCLA) is shown, showing the irregularly sized input facets 52 of the input lens 50 and the output facets 62 of the output lens 60. In particular, the wedge-shaped design of the input lens 50 with its input facets 52 is visible. The input lens 50 is designed as a whole in a wedge shape, with the sum of the input facets 52 forming this wedge shape. The wide portion of the wedge is located in the lower region of the input lens 50, while the narrow portion is located in the upper region. Due to this wedge shape, the distance between the input lens 50 and the output lens 60 varies across the height of the IFCLA. The distance to the output lens 60 is approximately 4.6 mm in the upper region and approximately 6.2 mm in the lower region. The wedge-shaped configuration of the input facets 52 enables the focal length of the output facets 62 to be irregular. This irregularity in the focal length facilitates precise formation of the light / dark boundary and enables fine-tuning of the vertical light distribution. The wedge shape allows for a slight defocusing of the output facets 62 , thereby enabling the hardness of the light-dark boundary to be adjusted to specific customer specifications.

[0069] Figure 9 The focal point of the input facet 52 is shown at the center of the corresponding output facet 62 of the irregular free-form cylindrical lens array IFCLA. The beam path of the light generated by one or more of the light sources 10 is shown through the input facets 52 of the input lens 50 and the output lens 60. Each input facet 52 focuses the incident light onto the center of the output facet 62 of the output lens 60 associated therewith. The focal point is located exactly at the center of the corresponding output facet 62. Due to the different sizes of the input facets 52, the beam paths differ slightly in their length and their angle.

[0070] Figure 10The focus of the output facet 62 is shown in the plane of the input facet 52 of the irregular free-form cylindrical lens array IFCLA. Here, the beam path is shown in the opposite direction. The focus of the output facet 62 lies in the plane of the input lens 50, more precisely in the plane of the input facet 52. This shows the bidirectional optical relationship between the input facet 52 and the output facet 62. The beam path shows how the light is directed by the output facet 62 and projected onto the roadway. Figure 9 and Figure 10 , , and , respectively, show how precise coordination of the beam paths through the input facets 52 and the output facets 62 contributes to efficient light deflection and the generation of the desired light distribution. This arrangement enables optimal superposition of the individual light beams and significantly contributes to the formation of the light-dark boundary and to uniform illumination of the roadway.

[0071] Figure 11 A perspective view of an irregular freeform lenticular lens array IFCLA is shown having an overhead logo area 80 in the output facet 62 of the output lens 60 . Figure 11 An irregular free-form lenticular lens array (IFCLA) is shown with a special overhead marking area 80, and Figure 12 The area where the individual output facets 62 overlap is shown. A special area for illuminating overhead signs is integrated into the center of the output lens 60. The input facets 52 in this area are designed so that they interact with the corresponding output facets 62 to deflect the light vertically upward by between +2° and +5°. This special design of the output facets 62 enables the illumination of traffic signs above the roadway without affecting the underlying light distribution.

[0072] Figure 12 The figure shows the overlapping area of ​​the individual output facets 62 of the irregular free-form cylindrical lens array (IFCLA), which helps to homogenize the light distribution. 1. Figure 12 The figure shows how the light distributions of the individual output facets 62 overlap. This overlap is the result of the precise design of the input facets 52, which deflect the light in a targeted manner toward the output facets 62. The different sizes and shapes of the input facets 52 contribute to the generation of this overlapping light distribution. This overlap results in a uniform overall light distribution on the roadway, while also producing a sharp light-dark boundary.

[0073] Figure 13A top view of a cylindrical lens array CLA is shown, along with the beam paths, which illustrate the horizontal spread of light. The coupling facets 32 of the CLA have a wavy profile, with each wave having a specific curvature. The beam paths illustrate the horizontal spread of light through the coupling facets 32. In the central region of the CLA, the coupling facets 32 have a flatter curvature. This results in less horizontal scattering of the light, which results in higher intensity and a wider range in the center of the light field. At the edges of the CLA, the coupling facets 32 have a more pronounced curvature. This results in a more intense horizontal scattering of the light, which results in a wider illumination in the edge regions. The different curvatures of the coupling facets 32 enable precise control of the horizontal light distribution through targeted deflection of the light beam. The beam paths illustrate how, after passing through the coupling facets 32, the light reaches the outcoupling facets and is further deflected there. The beam paths illustrate how the light passes through the input facets 52 of the IFCLA and is focused onto the output facets 62. The different sizes of the input facets 52 cause varying light refraction and light deflection, which helps produce the desired light distribution. In the middle of the IFCLA, the beam path tends to be straighter, indicating less light deflection in this area. At the edges of the IFCLA, the beam path shows a stronger deflection, which helps form the edge region of the light distribution. The beam paths illustrate how light, after passing through the input facets 52, reaches the output facets 62 and is further deflected there. The combination of the beam paths through the input facets 52 and output facets 62 of the IFCLA produces the desired horizontal and vertical light distributions, including precise light-dark boundaries. This special design of the input facets 52 and output facets 62 of the IFCLA and the resulting beam paths significantly contribute to efficient and precise light deflection, which enables an optimized light distribution for the vehicle headlamp 200, including the production of sharp light-dark boundaries and a gradual vertical light distribution. Each of the components shown is part of the vehicle headlamp 200.

[0074] Figure 14 A side view of a cylindrical lens array CLA is shown together with the light paths illustrating the vertical light distribution and the formation of the light-dark boundary. In particular, Figure 14A side view shows a section through the optical system 100 with a light path. The coupling-in facets 32 of the CLA are designed as a wave-shaped profile, wherein each wave has its own curvature. The light path shows how the incident light is refracted and deflected by the lenses of the CLA and the IFCLA via the collimator 20. In the central area of ​​the CLA, the coupling-in facets 32 have a flatter curvature, which causes less scattering of the light. This results in a higher intensity and a larger range of action of the light in this area. At the edges of the CLA, the coupling-in facets 32 have a more pronounced curvature, which causes a wider scattering of the light. This produces a large volume of light in the edge area. The different curvatures of the coupling-in facets 32 enable precise control of the horizontal light distribution. The light path shows how, after passing through the CLA, the light passes through the input facets 52 of the IFCLA and arrives at the coupling-out facets 62 and is further deflected there. The combination of the light paths through the input facet 52 and the outcoupling facet 62 produces the desired total light distribution having 1lx lines between ±30° and ±45°.

[0075] Reference Signs List

[0076] 10 light sources, LED

[0077] 20 collimators

[0078] CLA lenticular lens array

[0079] 30 coupling lens

[0080] 32 coupling facets

[0081] 40 outcoupling lens

[0082] 42 outcoupling facets

[0083] IFCLA irregular free-form cylindrical lens array

[0084] 50 Input Lens

[0085] 52 input facets

[0086] 60 output lens

[0087] 62 output facets

[0088] 70 boards

[0089] 72 spacer pins

[0090] 80 overhead sign area

[0091] 100 optical systems

[0092] 200 vehicle headlights

Claims

1. An optical system (100) for a vehicle headlamp (200), the optical system comprising: at least one light source (10), in particular at least one LED; at least one collimator (20) positioned so that it receives light from the light source (10); a lenticular lens array (CLA) positioned such that it receives collimated light from the at least one collimator (20); and an irregular freeform lenticular lens array (IFCLA), the irregular freeform lenticular lens array positioned such that it receives light from the lenticular lens array (CLA), The irregular free-form cylindrical lens array (IFCLA) comprises: an input lens (50) having a plurality of irregularly sized input facets (52) and an output lens (60) having a plurality of output facets (62), The irregularly sized input facets (52) of the input lens (50) focus light onto the center of the corresponding output facets (62) of the output lens (60).

2. The optical system (100) according to claim 1, characterized in that The lenticular lens array (CLA) is configured to provide horizontal diffusion of light, and the irregular freeform lenticular lens array (IFCLA) is configured to produce a horizontal light / dark boundary and a gradient vertical light distribution.

3. The optical system (100) according to claim 1 or 2, characterized in that The height of the input facet (52) of the input lens (50) of the irregular free-form cylindrical lens array (IFCLA) is between 0.03 mm and 0.6 mm, preferably between 0.06 mm and 0.6 mm.

4. The optical system (100) according to one of the preceding claims, characterized in that The height of the input facet (52) decreases at least regionally over the height of the entire input lens (50), in particular in steps of 20 mm to 60 mm.

5. The optical system (100) according to one of the preceding claims, characterized in that The input lens (50) is designed to be wedge-shaped.

6. The optical system (100) according to one of the preceding claims, characterized in that In the upper region, the distance between the input lens (50) and the output lens (60) is 4.2 mm to 5.0 mm, in particular 4.6 mm, and in the lower region, the distance between the input lens (50) and the output lens (60) is 5.8 mm to 6.6 mm, in particular 6.2 mm.

7. The optical system (100) according to one of the preceding claims, characterized in that All output facets (62) of the output lens (60) have the same height, and at least regionally, adjacent output facets (62) of the output lens (60) have different inclinations.

8. The optical system (100) according to one of the preceding claims, characterized in that The focal point of each input facet (52) is located at the center of the correspondingly assigned output facet (62).

9. The optical system (100) according to one of the preceding claims, characterized in that The focal point of each output facet (62) is located in the plane of the input lens (50), in particular in the plane of the input facet (52).

10. The optical system (100) according to one of the preceding claims, characterized in that The input lens (50) has at least 11 irregularly sized input facets (52).

11. The optical system (100) according to one of the preceding claims, characterized in that The cylindrical lens array (CLA) and the irregular free-form cylindrical lens array (IFCLA) comprise, particularly preferably consist of, a thermoplastic plastic material, in particular polycarbonate.

12. The optical system (100) according to one of the preceding claims, characterized in that The output lens (60) has an overhead marking area (80) in the output prism facet (62), in which a portion of the output prism facet (62) is designed so as to direct light vertically upwards at between +2 and +5 degrees.

13. The optical system (100) according to one of the preceding claims, characterized in that The cylindrical lens array (CLA) comprises a coupling-in lens (30) with a plurality of coupling-in facets (32) and a coupling-out lens (40) with a plurality of coupling-out facets (42), wherein the coupling-in facets (32) together form a wave-shaped profile, in particular, the curvature of the coupling-in facets (32) in a central region of the cylindrical lens array (CLA) is flatter than the curvature of the coupling-in facets (32) in an outer region of the cylindrical lens array (CLA).

14. The optical system (100) according to one of the preceding claims, characterized in that Structural elements, in particular rods, are applied by vacuum plasma etching to the surface of an input facet (52) of an input lens (50), to the surface of an output facet (62) of an output lens (60), and / or to the surface of an in-coupling facet (32) and / or an out-coupling facet (42) of a cylindrical lens array (CLA).

15. The optical system (100) according to one of the preceding claims, characterized in that The at least one light source (10) is arranged on a plate (70), and a spacer pin (72), in particular an adjustable spacer pin, is provided between the at least one collimator (20) and the plate (70) for orienting the at least one light source (10) relative to the at least one collimator (20).

16. Vehicle headlight (200), comprising an optical system (100) according to one of the preceding claims and a headlight housing arranged downstream of the optical system (100).

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