Headlamp assembly for a motor vehicle

Abstract

This invention relates to a headlight assembly for a motor vehicle, the headlight assembly including a light source and a plurality of optical elements disposed along an optical path with the light source. Each of the plurality of optical elements includes a plurality of transmission-enhancing features disposed on its surface. The plurality of transmission-enhancing features are configured to increase light transmission through the associated optical element and reduce reflection from the associated optical element.

Description

Cross-references to related applications

[0001] This invention patent application claims the benefit of U.S. Provisional Patent Application No. 63 / 743,316, filed January 9, 2025, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to vehicle headlight assemblies. Background Technology

[0003] This section provides background information relating to this disclosure, which is not necessarily prior art.

[0004] Modern vehicle headlights, or headlamps, consist of numerous optical elements used to transmit the light generated by a light source to illuminate the road. One drawback of modern headlights is that when the amount of light projected onto the road needs to be increased, the required housing size must be increased to accommodate the increased light source size. Furthermore, as the light output of the headlights increases, additional components are needed for heat dissipation, further increasing the size and cost of the headlight assembly. Summary of the Invention

[0005] This section provides a general overview of the disclosure and is not intended to be a complete enumeration of all features, advantages, aspects and objects associated with the inventive concept described and illustrated in the detailed description provided herein.

[0006] This disclosure provides a headlight assembly for a motor vehicle. The headlight assembly includes a light source and a plurality of optical elements disposed along an optical path with the light source. Each of the plurality of optical elements includes a plurality of transmission enhancement features disposed on a surface of the optical element and configured to increase light transmission through the optical element and reduce reflection from the optical element.

[0007] These and other aspects of this disclosure are disclosed in the following detailed description of the embodiments, the appended claims and the accompanying drawings. Attached Figure Description

[0008] The accompanying drawings described herein are for illustrative purposes only, illustrating selected non-limiting embodiments, and are not intended to limit the scope of this disclosure. In this regard, the drawings include:

[0009] Figure 1 The illustration shows a motor vehicle with a headlight assembly according to one aspect of the present disclosure;

[0010] Figure 2 An exploded view of a vehicle headlight assembly according to an illustrative embodiment is shown.

[0011] Figures 3 to 4The diagram illustrates the structure and characteristics of the optical elements of a headlight assembly, which has nanostructures disposed on the surface of the optical elements. Detailed Implementation

[0012] The present invention will be described in detail below with reference to the accompanying drawings.

[0013] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. Exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous examples of specific details, such as particular components, apparatuses, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that the exemplary embodiments may be implemented in many different forms, and that neither the specific details nor the exemplary embodiments should be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0014] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore specify the presence of the described features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof. Unless specifically indicated in the order of execution, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the particular order discussed or described. It should also be understood that additional or alternative steps may be employed.

[0015] When an element or layer is described as being “on,” “joined to,” “connected to,” or “attached to” another element or layer, the element or layer may be directly on, joined to, connected to, or attached to the other element or layer, or there may be intermediate elements or layers present. In contrast, when an element is described as being “directly on,” “directly joined to,” “directly connected to,” or “directly attached to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in the same manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0016] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another region, layer, or segment. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply any order or sequence. Therefore, the first element, first component, first region, first layer, or first segment discussed below may be referred to as a second element, second component, second region, second layer, or second segment without departing from the teachings of the exemplary embodiments.

[0017] For ease of explanation, spatial relative terms such as “inner,” “outer,” “below,” “below,” “down,” “above,” “up,” etc., are used herein to describe the relationship between one element or feature and another element or feature as shown in the accompanying drawings. Spatial relative terms may be intended to cover different orientations of the device in use or operation other than those depicted in the drawings. For example, if the device in the drawings is flipped, an element described as “below other elements or features” or “below other elements or features” will be oriented “above other elements or features.” Thus, the example term “below” can include both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein are interpreted accordingly.

[0018] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “including,” “containing,” and “having” are inclusive and therefore specify the presence of the described features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof. Unless specifically indicated in the order of execution, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the particular order discussed or described. It should also be understood that additional or alternative steps may be employed.

[0019] When an element or layer is described as being “on,” “joined to,” “connected to,” or “attached to” another element or layer, the element or layer may be directly on, joined to, connected to, or attached to the other element or layer, or there may be intermediate elements or layers present. In contrast, when an element is described as being “directly on,” “directly joined to,” “directly connected to,” or “directly attached to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in the same manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0020] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another region, layer, or segment. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply any order or sequence. Therefore, the first element, first component, first region, first layer, or first segment discussed below may be referred to as a second element, second component, second region, second layer, or second segment without departing from the teachings of the exemplary embodiments.

[0021] For ease of explanation, spatial relative terms such as “inner,” “outer,” “below,” “below,” “down,” “above,” “top,” “bottom,” etc., are used herein to describe the relationship between one element or feature and another element or feature as shown in the accompanying drawings. Spatial relative terms may be intended to cover different orientations of the device in use or operation other than those depicted in the drawings. For example, if the device in the drawings is flipped, an element described as “below other elements or features” or “below other elements or features” will be oriented “above other elements or features.” Thus, the example term “below” can include both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein are interpreted accordingly.

[0022] Reference Figure 1 The illustration shows a vehicle 10, such as an automobile, with two headlight assemblies 12A and 12B. These two headlight assemblies include a right headlight assembly 12A and a left headlight assembly 12B.

[0023] Now refer to Figure 2An exploded view of a lamp assembly 20 for one of headlight assemblies 12A and 12B is shown. The lamp assembly 20 includes a heat sink 30 and a printed circuit board (PCB) 32 disposed on the heat sink 30. One or more light sources 33, such as LED devices, are disposed on the PCB 32, and the one or more light sources 33 are configured to produce light. The one or more light sources 33 may include an LED array having associated power electronics. A housing 34 surrounds the PCB 32. A lens holder 38 is attached to the housing 34 using a plurality of screws 36.

[0024] The lamp assembly 20 also includes a plurality of optical elements optically coupled to each other. More specifically, the optical elements in the lamp assembly 20 include a plurality of lenses 40, 44, 48, 52 arranged along an optical path to focus and guide light generated by one or more light sources 33. However, other types of optical elements, such as filters, mirrors, and / or prisms, may be used. The plurality of lenses 40, 44, 48, 52 includes a first lens 40, a second lens 44, a third lens 48, and a fourth lens 52. The first lens 40 is arranged adjacent to one or more light sources 33 for receiving light from one or more light sources 33, and the second lens 44 is the next adjacent lens in the optical path for receiving light from the first lens 40. The lamp assembly 20 also includes a first spacer ring 42 of an annular shape disposed between the first lens 40 and the second lens 44 to maintain a predetermined distance between the first lens 40 and the second lens 44.

[0025] The third lens 48 is the next adjacent lens in the optical path for receiving light from the second lens 44. The lamp assembly 20 also includes a second annular spacer ring 46 disposed between the second lens 44 and the third lens 48 to maintain a predetermined distance between them. The fourth lens 52 is the next adjacent lens in the optical path for receiving light from the third lens 48. The lamp assembly 20 also includes a third annular spacer ring 50 disposed between the third lens 48 and the fourth lens 52 to maintain a predetermined distance between them.

[0026] The lamp assembly 20 also includes a cover 56 having a tubular body 58 surrounding a plurality of lenses 40, 44, 48, 52 and a lens holder 38. The lamp assembly 20 also includes a fourth spacer ring 54 of an annular shape disposed between the fourth lens 52 and the cover 56 to maintain a predetermined distance between the fourth lens 52 and the cover 56. The fourth spacer ring 54 may be made of an elastic material to prevent vibration between the fourth lens 52 and the cover 56. The cover 56 includes a protrusion 60 extending rearward toward the housing 34. The protrusion 60 defines an opening 62. The lens holder 38 includes an upwardly extending projection 64 configured to fit into the opening 62 in the protrusion 60 of the cover 56 to hold the cover 56 to the lens holder 38 and the housing 34.

[0027] The cover 56 also defines a recess 66 opposite to the plurality of lenses 40, 44, 48, 52. A lens cover 68 is disposed in the recess 66, thereby covering the fourth lens 52. The lens cover 68 can be configured, for example, by including two parallel surfaces to allow light to pass through the lens cover without distortion.

[0028] like Figures 3 to 4 As shown, each of the multiple lenses 40, 44, 48, and 52 includes a surface 84 with a nanostructure. Table 1 below lists the transmission efficiencies at various optical interfaces of the vehicle headlight assembly.

[0029] As indicated, the first lens 40 may be made of glass. The second lens 44, the third lens 48, and the fourth lens 52 may each be made of polymethyl methacrylate (PMMA), and the lens cover 68 may be made of polycarbonate (PC). However, any or all of the lenses 40, 44, 48, 52, and / or the lens cover 68 may be made of different materials.

[0030] Figure 3 A schematic cross-section of optical element 80 is shown. Optical element 80 may describe any or all of lenses 40, 44, 48, and 52 in lamp assembly 20. Optical element 80 includes a substrate 82 defining a surface 84. Substrate 82 may have a first refractive index n. S Multiple nanostructures 86 protrude from the surface 84 of the substrate 82. The multiple nanostructures 86 may be formed together on the surface 84 of the substrate 82 as an additional optical layer, for example, by applying a film 88 to the surface 84 of the substrate 82. Alternatively, the multiple nanostructures 86 may be integrally formed with the substrate 82 of the optical element 80.

[0031] Figure 3The diagram also illustrates the distance d between corresponding portions of two adjacent nanostructures in nanostructure 86 in a direction parallel to surface 84. Nanostructure 86 can define a regular pattern in which the distance d between corresponding portions of each adjacent nanostructure in nanostructure 86 is the same. Alternatively, the distance d between corresponding portions of two adjacent nanostructures in nanostructure 86 can be different in a direction parallel to surface 84. For example, as... Figure 3 As shown in the two middle nanostructures 86, these two adjacent nanostructures in nanostructure 86 can contact each other at their respective positions where they meet the surface 84, while each middle nanostructure in nanostructure 86 is spaced apart from the other nanostructures in nanostructure 86, such as... Figure 3 As shown on the far left and far right.

[0032] Figure 3 The height h of nanostructure 86 in the direction perpendicular to surface 84 is also illustrated. Each nanostructure in nanostructure 86 may have the same height h. Figure 4 A graph illustrating the relationship between the height h of the nanostructure 86 and the difference in refractive index (n) is shown. As illustrated, the nanostructure 86 defines the refractive index (n), which gradually increases with height h. More specifically, from the first refractive index n of the substrate 82... S Initially, the refractive index (n) increases linearly with height h. The nanostructure 86 is shown as having a constant slope, and therefore, the refractive index (n) varies proportionally with the distance along a direction parallel to surface 84. However, the nanostructure 86 can have different physical arrangements or structures.

[0033] Each of lenses 40, 44, 48, and 52 may have nanostructures 86 applied to each of its surfaces, such as nanostructures applied to two opposite sides of each lens. Lens cover 68 may also have nanostructures 86 applied to each of its surfaces. Therefore, the nanostructures 86 can improve the optical efficiency of the headlight assemblies 12A and 12B by increasing light transmission from the light source and reducing reflection. Consequently, the light output of the light source can be reduced, and the size of the light source can be decreased, thereby reducing the size and cost of the lamp assembly. Furthermore, the LED array of the light source can be selected to emit less light, thus saving costs. Additionally, the power loss of the light source 33 can be reduced, thereby providing energy efficiency and correspondingly eliminating or reducing the size of heat dissipation elements. For example, the lamp assembly 20 may not require a heat sink, and therefore the headlight assembly may also be without a heat sink, resulting in significant cost savings, reduced package size, and lighter weight.

[0034] This disclosure provides a headlight assembly for a motor vehicle. The headlight assembly includes a light source and a plurality of optical elements disposed along an optical path with the light source. Each of the plurality of optical elements includes a plurality of transmission-enhancing features disposed on a surface of the optical element and configured to increase light transmission through the optical element and reduce reflection from the optical element. For example, compared to a similar or identical optical element without transmission-enhancing features, the plurality of transmission-enhancing features can give the associated optical element increased light transmission characteristics and reduced reflectivity. In some cases, including a plurality of transmission-enhancing features can give the associated optical element significantly increased light transmission characteristics compared to a similar or identical optical element without transmission-enhancing features.

[0035] In some embodiments, each of a plurality of optical elements defines an input surface and an output surface, the input surface being for receiving light from a light source and the output surface being for emitting light therefrom, and wherein a plurality of transmission enhancement features are disposed on each of the input surface and the output surface.

[0036] In some embodiments, each of a plurality of optical elements defines a surface, wherein a plurality of transmission enhancement features are disposed on the surface.

[0037] In some implementations, multiple transmission enhancement features include nanostructures formed on the surface of the optical element.

[0038] In some embodiments, the nanostructure is defined by a regular pattern, wherein the distance between corresponding portions of adjacent nanostructures is the same.

[0039] In some embodiments, the nanostructure defines an irregular pattern, wherein the distance between corresponding portions of adjacent nanostructures in the nanostructure is different.

[0040] In some embodiments, at least some of the nanostructures in the nanostructure contact adjacent nanostructures in the nanostructure at their respective locations in contact with the surface.

[0041] In some implementations, the nanostructures have the same height in a direction perpendicular to the surface.

[0042] In some implementations, each nanostructure has a refractive index that varies with its height perpendicular to the surface.

[0043] In some implementations, each nanostructure has a refractive index that varies along a direction parallel to the surface.

[0044] In some implementations, the refractive index of each nanostructure in the nanostructure varies proportionally to the distance along a direction parallel to the surface.

[0045] In some embodiments, the headlight assembly also includes a material film disposed on the surface of each optical element, and the film includes multiple transmission enhancement features.

[0046] In some implementations, multiple transmission enhancement features are integrally formed with each optical element.

[0047] In some implementations, the multiple optical elements include multiple lenses, each configured to focus and guide light from a light source.

[0048] In some embodiments, the plurality of optical elements further include a lens cover covering the plurality of lenses, wherein the lens cover is configured to allow light to pass through the lens cover without distortion, and wherein the lens cover includes a plurality of additional transmission enhancement features configured to increase light transmission through the lens cover and reduce reflection from the lens cover.

[0049] In some implementations, the headlight assembly does not include a heat sink.

[0050] A prior description of embodiments has been provided for purposes of illustration and description. This prior description is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. Elements or features of a particular embodiment may also be varied in many ways. Such variations are not considered to depart from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A headlight assembly (12A, 12B) for a motor vehicle (10), the headlight assembly (12A, 12B) comprising: Light source (33); as well as Multiple optical elements (80) are arranged along an optical path with the light source (33). Each of the plurality of optical elements (80) includes a plurality of transmission enhancement features disposed on the surface (84) of the optical element (80) and configured to increase light transmission through the optical element (80) and reduce reflection from the optical element (80).

2. The headlight assembly (12A, 12B) according to claim 1, wherein, Each of the plurality of optical elements (80) defines an input surface (84) and an output surface (84), the input surface (84) for receiving light from the light source and the output surface (84) for emitting light from the output surface (84), wherein the plurality of transmission enhancement features are disposed on each of the input surface (84) and the output surface (84).

3. The headlight assembly (12A, 12B) according to claim 1, wherein, Each of the plurality of optical elements (80) defines a surface (84), wherein the plurality of transmission enhancement features are disposed on the surface (84).

4. The headlight assembly (12A, 12B) according to claim 3, wherein, The plurality of transmission enhancement features include nanostructures (86) formed on the surface (84) of the optical element (80).

5. The headlight assembly (12A, 12B) according to claim 4, wherein, The nanostructure (86) defines a regular pattern, wherein corresponding portions of adjacent nanostructures in the nanostructure (86) have the same distance.

6. The headlight assembly (12A, 12B) according to claim 4, wherein, The nanostructure (86) defines an irregular pattern, wherein corresponding portions of adjacent nanostructures in the nanostructure (86) have different distances.

7. The headlight assembly (12A, 12B) according to claim 4, wherein, Each of the nanostructures (86) has the same height in a direction perpendicular to the surface (84).

8. The headlight assembly (12A, 12B) according to claim 4, wherein, Each of the nanostructures (86) has a refractive index that varies with the height perpendicular to the surface (84).

9. The headlight assembly (12A, 12B) according to claim 4, wherein, Each of the nanostructures (86) has a refractive index that varies along a direction parallel to the surface (84).

10. The headlight assembly (12A, 12B) according to claim 9, wherein, The refractive index of each nanostructure in the nanostructure (86) varies proportionally with the distance along the direction parallel to the surface (84).

11. The headlight assembly (12A, 12B) according to claim 1, further comprising a material film (88) disposed on the surface (84) of each optical element (80), wherein, The membrane (88) includes the plurality of transmission enhancement features.

12. The headlight assembly (12A, 12B) according to claim 1, wherein, The plurality of transmission enhancement features are integrally formed with each optical element (80).

13. The headlight assembly (12A, 12B) according to claim 1, wherein, The plurality of optical elements (80) include a plurality of lenses (40, 44, 48, 52), each lens being configured to focus and guide light from the light source.

14. The headlight assembly (12A, 12B) according to claim 13, wherein, The plurality of optical elements (80) further include a lens cover (68) covering the plurality of lenses (40, 44, 48, 52), wherein the lens cover (68) is configured to allow light to pass through the lens cover (68) without distortion, and wherein the lens cover (68) includes a plurality of additional transmission enhancement features configured to increase light transmission through the lens cover (68) and reduce reflection from the lens cover (68).

15. The headlight assembly (12A, 12B) according to claim 1, wherein, The headlight assemblies (12A, 12B) do not include a heat sink.

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