LED unit, headlamp module and vehicle

Abstract

The utility model discloses a light emitting diode (LED) unit, a headlamp module and a vehicle, and relates to a headlamp module and a vehicle. The LED unit is used for a headlamp module of a vehicle. The LED unit includes an LED and a lens. The LED is used for emitting light. The lens is arranged on a light-emitting light path of the LED. The LED is located on the focal plane of the lens. The lens carries out beam shaping on light rays emitted by the LED to form illumination light spots. Each LED unit is formed by packaging an LED and a lens corresponding to the LED, and the LED units form the headlamp module. According to the headlamp module, a shading plate structure is removed from the LED unit, the number of elements of the LED unit and the specific interval of optical design needed by the shading plate are reduced, and therefore the size of the headlamp module is reduced. The offset of the optical axis of the LED and the optical axis of the lens enables different LED units in the headlamp module to project illumination light spots, and the size of the headlamp module is further reduced due to the mapping from small-size LED units to large-size light patterns.

Description

Technical Field

[0001] This application relates to the technical field of vehicle lighting, and particularly to a Light Emitting Diode (LED) unit, a headlamp module, and a vehicle. Background Art

[0002] The miniaturization of the size of automotive headlamp modules and the flattened design of the openings are one of the main development directions of current automotive lamps. The current solutions for miniaturized headlamp modules mainly adopt the "multi-unit combination" solution instead of the traditional "integrated" solution, that is, by reducing the size and spacing of each component to achieve the purpose of volume reduction. After years of development and accumulation in the industry, various miniaturization solutions have been proposed and mass-produced.

[0003] However, since the current mainstream solutions follow the traditional method in optical design, that is, using structures such as reflectors and light shields, the number of components is relatively large, and specific spacing needs to be satisfied between components for optical design. Therefore, the headlamp module is restricted in aspects such as the arrangement method of each unit, further miniaturization, and the difficulty of unit packaging. Summary of the Invention

[0004] This application provides an LED unit, a headlamp module, and a vehicle.

[0005] In a first aspect, an embodiment of this application provides an LED unit for a headlamp module of a vehicle. The LED unit includes an LED and a lens. The LED is used to emit light. The lens is disposed on the light-emitting optical path of the LED. The LED is located on the focal plane of the lens. The lens performs beam shaping on the light emitted by the LED to form an illumination spot with a specific energy distribution characteristic.

[0006] In some embodiments, the LED and the lens are coaxial.

[0007] In some embodiments, the optical axis of the LED is offset from the optical axis of the lens.

[0008] In some embodiments, the optical axis of the LED is offset from the optical axis of the lens, and the offset distance between the optical axis of the LED and the optical axis of the lens is positively correlated with the distance between the center of the optical axis of the LED unit and the headlamp module.

[0009] In some embodiments, the offset distance between the optical axis of the LED and the optical axis of the lens includes a first distance in a first direction and a second distance in a second direction. The first distance is related to the effective focal length f of the lens and the angle h of the light spot projected by the LED unit in the first direction. The second distance is related to the effective focal length f of the lens and the angle v of the light spot projected by the LED unit in the second direction. Wherein, -35° < h < 35°, -10° < v < 0°.

[0010] In some embodiments, the number of the LEDs is one or more. Each of the LEDs can be independently controlled so that the LED unit can project light spots with different light patterns.

[0011] In some embodiments, the lens includes an incident light surface and an emergent light surface facing away from each other, and the incident light surface is closer to the LED than the emergent light surface. The incident light surface is a plane, an aspherical surface or a free-form surface; and / or the emergent light surface is a spherical surface, an aspherical surface or a free-form surface.

[0012] In some embodiments, the lens is a single microlens.

[0013] In some embodiments, there are multiple lenses. The multiple lenses are arranged in sequence along the light emitting direction of the LED.

[0014] In some embodiments, the LED unit further includes a support member. The support member is formed with a receiving cavity. The LED is received in the receiving cavity. The lens is supported on the support member.

[0015] In some embodiments, the LED unit further includes a base, and the support member includes a support body and an extension portion. The support body defines the receiving cavity and is carried on the base. The extension portion extends from the inner wall of the support body towards the center of the receiving cavity. The lens is supported on the extension portion.

[0016] In some embodiments, the support member includes a bottom wall and a side wall. The bottom wall and the side wall define the receiving cavity. The base is carried on the bottom wall and is located within the receiving cavity. The lens is supported on the top of the side wall.

[0017] In some embodiments, the support member is an optical adhesive. The bottom of the optical adhesive is carried on the base. The lens is supported on the top of the optical adhesive. The optical adhesive is filled between the base and the lens.

[0018] In some embodiments, the LED unit further includes a substrate and a reflector bowl structure disposed on the substrate. The reflector bowl structure is provided with a reflecting cavity. The LED is located in the reflecting cavity. The inner wall of the reflecting cavity is provided with a reflective layer. The reflective layer is used to reflect the light emitted by the LED to the lens.

[0019] In some embodiments, the illumination spot is configured as a low beam light pattern and / or a high beam light pattern.

[0020] In a second aspect, an embodiment of the present application provides a headlamp module, which includes the LED unit according to any one of the above embodiments.

[0021] In a third aspect, an embodiment of the present application provides a headlamp module, which includes a plurality of LED units. Each LED unit includes a substrate, an LED, and a lens. The LED is mounted on the substrate and electrically connected to the substrate. The LED is used to emit light. The lens assembly is disposed on the light-emitting optical path of the LED. Among them, the plurality of LED units are distributed in an array. In at least some of the LED units, the optical axis of the LED is offset from the optical axis of the lens, so that the LED unit forms an illumination spot with a specific energy distribution characteristic.

[0022] In some embodiments, in the LED unit, the offset distance between the optical axis of the LED and the optical axis of the lens is positively correlated with the distance between the LED unit and the optical axis center of the headlamp module.

[0023] In some embodiments, the LED is located on the focal plane of the lens. The offset distance between the optical axis of the LED and the optical axis of the lens includes a first distance along a first direction and a second distance along a second direction. The first distance is related to the effective focal length f of the lens and the angle h of the spot projected by the LED unit in the first direction. The second distance is related to the effective focal length f of the lens and the angle v of the spot projected by the LED unit in the second direction. Among them, -35° < h < 35°, -10° < v < 0°.

[0024] In some embodiments, the number of LEDs is one or more. Each LED can be independently controlled so that the LED unit can project spots of different light patterns.

[0025] In some embodiments, the lens includes an incident light surface and an exit light surface facing away from each other. The incident light surface is closer to the LED than the exit light surface. The incident light surface and the exit light surface are plane, aspherical, or free-form surfaces.

[0026] In some embodiments, the lens includes an incident light surface and an emergent light surface facing away from each other. The incident light surface is closer to the LED than the emergent light surface. The incident light surface is a plane, an aspherical surface or a free-form surface, or the emergent light surface is a spherical surface, an aspherical surface or a free-form surface.

[0027] In some embodiments, the lens is a single microlens.

[0028] In some embodiments, the lens includes a plurality of microlenses. The plurality of lenses are arranged in sequence along the light-emitting direction of the LED.

[0029] In some embodiments, the LED unit further includes a support member. The support member is formed with a receiving cavity. The LED is received in the receiving cavity. The lens is supported on the support member.

[0030] In some embodiments, the support member includes a support body and an extension portion. The support body defines the receiving cavity and is carried on the substrate. The extension portion extends from the inner wall of the support body towards the center of the receiving cavity. The lens is supported on the extension portion.

[0031] In some embodiments, the support member includes a bottom wall and a side wall. The bottom wall and the side wall define the receiving cavity. The substrate is carried on the bottom wall and is located within the receiving cavity. The lens is supported on the top of the side wall.

[0032] In some embodiments, the support member is an optical adhesive. The bottom of the optical adhesive is carried on the substrate. The lens is supported on the top of the optical adhesive. The optical adhesive is filled between the substrate and the lens.

[0033] In some embodiments, the LED unit further includes a reflecting bowl structure disposed on the substrate. The reflecting bowl structure is provided with a reflecting cavity. The LED is located within the reflecting cavity. The inner wall of the reflecting cavity is provided with a reflecting layer. The reflecting layer is configured to reflect the light emitted by the LED to the lens.

[0034] In some embodiments, the illumination light spot is configured as a low beam light pattern and / or a high beam light pattern.

[0035] In a fourth aspect, an embodiment of the present application provides a vehicle, which includes the headlight module according to any one of the above embodiments.

[0036] In the LED unit, headlamp module, and vehicle of the present application, the LED unit is formed by encapsulating an LED and a lens corresponding to the LED. A plurality of LED units form a headlamp module. On the one hand, the LED unit eliminates the light shielding plate structure, reducing the number of components in the LED unit and the specific spacing required for the optical design of the light shielding plate, thereby reducing the size of the headlamp module. On the other hand, the offset between the LED optical axis and the lens optical axis in the LED unit enables different LED units in the headlamp module to project illumination spots with specific energy distribution characteristics, completing the mapping from small-sized LED units to large-sized light patterns, further reducing the size of the headlamp module and optimizing the arrangement of the LED units.

[0037] Furthermore, since the number of components encapsulated in the LED unit is small and the alignment relationship between the components is simple, the alignment difficulty between the components encapsulated in the LED unit can be reduced, ensuring accurate encapsulation.

[0038] Some additional aspects and advantages of the present application will be given in part in the following description, some will become apparent from the following description, or will be understood through the practice of the present application. Description of the Drawings

[0039] The above and / or additional aspects and advantages of the present application will become apparent and easy to understand from the description of the embodiments in conjunction with the following drawings, where:

[0040] Figure 1 is a schematic structural diagram of a headlamp module according to some embodiments of the present application;

[0041] Figure 2 is a schematic structural diagram of a headlamp module according to some other embodiments of the present application;

[0042] Figure 3 is a schematic structural diagram of a headlamp module according to still some other embodiments of the present application;

[0043] Figure 4 is a schematic structural diagram of an LED unit according to some embodiments of the present application;

[0044] Figure 5 is a schematic structural diagram of an LED unit according to some other embodiments of the present application;

[0045] Figure 6 is a schematic diagram showing the spots projected by an LED unit according to some embodiments of the present application forming a low beam light pattern;

[0046] Figure 7 is Figure 4 a schematic optical diagram of the spots projected by the LED unit shown;

[0047] Figure 8It is a schematic diagram of the light spots of multiple LEDs with different light patterns in some embodiments of the present application;

[0048] Figure 9 It is a schematic structural diagram of an LED unit in some other embodiments of the present application;

[0049] Figure 10 It is a schematic structural diagram of an LED unit in some other embodiments of the present application;

[0050] Figure 11 It is a schematic structural diagram of an LED unit in some other embodiments of the present application;

[0051] Figure 12 It is a schematic structural diagram of an LED unit in some other embodiments of the present application;

[0052] Figure 13 It is a schematic structural diagram of a headlight module of a vehicle in some embodiments of the present application.

[0053] Description of main component numbers:

[0054] Vehicle 1000, headlight module 100, LED unit 10, substrate 11, LED 13, lens 15, light incident surface 151, light exit surface 153, support member 17, accommodation cavity 171, support body 173, extension portion 175, bottom wall 177, side wall 178, optical glue 179, reflector bowl structure 19, reflection cavity 191, reflection layer 1911. Specific embodiments

[0055] In the description of the present application, some of the disclosed content has been correspondingly shown in the drawings, where the same or similar reference numerals represent the same or similar elements or elements with the same or similar functions from beginning to end. The content described below by referring to the drawings is exemplary and is only used to explain the present application and cannot be construed as a limitation to the present application.

[0056] In the description of the present application, many different contents or examples are disclosed to implement different structures of the present application. To simplify the disclosure of the present application, the components and settings of specific examples are described below. Of course, they are only examples and are not intended to limit the present application.

[0057] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present application, "a plurality" means two or more unless otherwise specifically defined.

[0058] In the description of the present application, it should be understood that the terms used to indicate orientation or positional relationship (such as "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc.) are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and facilitating the understanding of the corresponding embodiments, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the terms used to indicate orientation or positional relationship should not be construed as a limitation of the present application.

[0059] In the description of the present application, unless otherwise clearly specified and limited, the first feature being "on" or "under" the second feature may include the first and second features being in direct contact, or may include the first and second features not being in direct contact but being in contact through additional features therebetween. Moreover, the first feature being "above", "over" and "on top of" the second feature includes the first feature being directly above and obliquely above the second feature, or merely indicating that the first feature has a higher horizontal height than the second feature. The first feature being "under", "beneath" and "underneath" the second feature includes the first feature being directly below and obliquely below the second feature, or merely indicating that the first feature has a lower horizontal height than the second feature.

[0060] In the description of the present application, it should be noted that, unless otherwise clearly specified and limited, the terms "mounted", "connected" and "coupled" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection. It may be a mechanical connection or an electrical connection. It may be directly connected or indirectly connected through an intermediate medium, and may be the internal communication of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present application can be understood according to specific circumstances.

[0061] The headlamp of a vehicle, also known as the headlight or front headlamp, is an important safety and appearance component of the vehicle. The headlamp has multiple functions such as illumination, signaling, and improving visibility, and can ensure driving safety at night and under low visibility conditions. The position of the headlamp is usually located at the front end of the vehicle 1000, generally on both sides of the vehicle, and is adapted to the width of the vehicle to ensure sufficient vision for the driver during driving. In modern vehicle design, the headlamp is also an important part of the vehicle appearance. The headlamp can enhance the aesthetics and recognition of the vehicle through different designs and lighting effects. Innovation and breakthroughs in vehicle styling are also an important direction for the development of the vehicle 1000 industry at the present stage.

[0062] However, due to the complex structure and large volume of the headlamp, the front body of the vehicle often has to reserve a specific position and a large area of space for the headlamp, resulting in a serious restriction on the freedom of vehicle styling. To solve the problem that the freedom of vehicle styling is limited by the large volume of the headlamp and to innovate the structure of the headlamp of traditional vehicles, it is an inevitable choice to reduce the volume of the light source module. After years of development, the size of the light exit aperture of the headlamp module has been reduced from the order of about 200*100 mm to the order of 100*15 mm. However, the size is still not small enough and needs to be further optimized to improve the freedom of the overall appearance styling of the vehicle.

[0063] In the early stage, the headlamp module adopted an integrated structure, that is, a module composed of an LED, a reflector, a light pattern shading plate, and a light distribution lens. Since the size of each component itself is large, and a specific spacing needs to be satisfied between the components for optical design, that is, the spacing between the components is large, the final size of the headlamp module is large, and the size of the light exit aperture of the headlamp module is about 200*100 mm. Recently, the headlamp module has been preliminarily miniaturized and adopts a combination of several LED units to jointly meet the requirements of the low beam and / or high beam light patterns. The combination method of several LED units is divided into two categories. One is the reflective structure, that is, each LED unit still uses the early module structure, which is composed of an LED, a reflector, a shading plate, and a light distribution lens. At this time, the LED unit only needs to be responsible for illuminating a certain part of the low beam and / or high beam light pattern. Several LED units are combined to achieve the splicing of each illuminated area, so as to form the low beam and / or high beam light pattern. Therefore, in each LED unit, the size of the LED and other components is reduced compared with the early integrated structure. However, at this time, the number of components in the LED unit is large, resulting in the size of the LED unit not being small enough. The other is the direct transmission structure, that is, each LED unit no longer needs a reflector. The light emitted by the LED forms a corresponding illuminated area after being shaped by the lens and the shading plate. Finally, several LED units are combined to form the low beam / high beam light pattern. However, at this time, the LED unit includes the LED, the lens, and the shading plate structure.

[0064] Please refer to Figure 1 and Figure 2 , an embodiment of the present application provides a headlamp module 100. The headlamp module 100 includes a plurality of LED units 10. Please combine Figure 4 , Figure 5 , Figure 9 , Figure 10 , Figure 11 or Figure 12Each LED unit 10 includes a substrate 11, an LED 13 and a lens 15. The LED 13 is mounted on the substrate 11 and electrically connected to the substrate 11. The LED 13 is used to emit light. The lens 15 is arranged on the light path of the LED 13. Among them, a plurality of LED units 10 are distributed in an array. In at least some of the LED units 10, the optical axis of the LED 13 is offset from the optical axis of the lens 15, so that the LED unit forms an illumination spot with a specific energy distribution characteristic.

[0065] The substrate 11 is a circuit board that provides support and power for the LED 13. On the one hand, the substrate 11 provides physical support for the LED 13 to ensure that the LED 13 can be fixed on the substrate 11. On the other hand, the substrate 11 can electrically connect the LED 13 to the power supply unit through the line, and the power supply unit can provide power to the LED 13 so that the LED 13 emits light outward; the substrate 11 can also electrically connect the LED 13 to the controller through the line, and the controller can control the opening time, brightness, power and frequency of the light emitted by the LED 13.

[0066] LED 13 is a semiconductor device that can convert electrical energy into light energy. LED 13 has the advantages of small size, low power consumption, long life, high brightness, etc. In the present application, LED 13 can be at least one of an LED that emits red light, an LED that emits green light, an LED that emits blue light, and an LED that emits white light. The illumination light spot with a specific energy distribution characteristic in the LED unit 10 can form a low beam light type and / or a high beam light type, or can form other light types. The present application only takes the LED unit 10 forming a low beam light type and / or a high beam light type as an example for explanation.

[0067] The lens 15 is usually made of a light-transmitting material, including but not limited to glass and plastic. The lens 15 has a specific curved shape. The lens 15 changes the propagation direction of light by refracting light. In the present application, the lens 15 is used to shape the light beam of the LED 13. Therefore, any integrated optical device that can shape the light beam of the LED 13 can be applied to the LED unit 10. In other embodiments of the present application, the LED unit 10 can use the lens 15, or an optical device such as a reflector, or a lens 15 combined with a reflector.

[0068] The array distribution of the plurality of LED units 10 includes: the plurality of LED units 10 are distributed in a rectangular array, such as Figure 1 and Figure 2 As shown, the plurality of LED units 10 are arranged in an array, and the plurality of LED units 10 are arranged in a circular array. Figure 1 , multiple LED units 10 can be arranged into a 2*5 rectangular array; Figure 2, multiple LED units 10 can be arranged in a 3×3 rectangular array. It can be understood that multiple LED units 10 can be arranged in other forms of arrays, such as Figure 3 the stepped array shown, which is not limited here.

[0069] Please refer to Figure 2 and Figure 5 , in the embodiments of the present application, the first direction is the X-axis direction, the second direction is the Y-axis direction, and the third direction is the Z-axis direction. The third direction Z is also the light emitting optical path direction of the LED 13 in this embodiment. "The optical axis of the LED 13 is offset from the optical axis of the lens 15" means that: in the plane XY perpendicular to the optical axis M of the lens 15, there is a certain offset distance Δd between the projection center of the LED 13 and the projection center of the lens 15. In one example, in the array of LED units 10, the offset distance Δd in some of the LED units 10 is the same, and the offset distance Δd in some other LED units 10 is different. Taking Figure 2 the 3×3 LED unit array shown as an example, among them, the distances from the centers of the LED units 10a, 10c, 10g, and 10i in the XY plane to the center O of the headlight module 100 in the XY plane are all h1. In the LED units 10a, 10c, 10g, and 10i, the offset distance Δd between the projection center of the LED 13 in the XY plane and the projection center of the lens 15 in the XY plane is the same, for example, all Δd1. The distances from the centers of the LED units 10b, 10d, 10f, and 10h in the XY plane to the center O of the headlight module 100 in the XY plane are all h2. In the LED units 10b, 10d, 10f, and 10h, the offset distance Δd between the projection center of the LED 13 in the XY plane and the projection center of the lens 15 in the XY plane is the same, for example, all Δd2. Among them, Δd1≠Δd2. Preferably, Δd1>Δd2.

[0070] In another example, please refer to Figure 3 and Figure 5, in the array of LED units 10, the offset distances Δd in all LED units 10 are different. There are a total of 9 LED units 10 in the array of LED units 10, namely LED unit 10a to LED unit 10i. The distances between the unit centers of each LED unit 10 and the center O of the headlight module 100 are not the same, which are h1 to h9 respectively. The offset distance Δd in each LED unit 10 is different. Specifically, the offset distance in LED unit 10a is Δd1, the offset distance in LED unit 10b is Δd2, the offset distance in LED unit 10c is Δd3, the offset distance in LED unit 10d is Δd4, the offset distance in LED unit 10e is Δd5, the offset distance in LED unit 10f is Δd6, the offset distance in LED unit 10g is Δd7, the offset distance in LED unit 10h is Δd8, and the offset distance in LED unit 10i is Δd9, where Δd1≠Δd2≠Δd3≠Δd4≠Δd5≠Δd6≠Δd7≠Δd8≠Δd9.

[0071] Specifically, please refer to Figure 1 and Figure 6 , the headlight module 100 regulates and combines the light spots emitted by each LED unit 10, so as to form a low beam light pattern and / or a high beam light pattern that meets the regulatory requirements, such as Figure 6As shown. Among them, the low beam light pattern and / or the high beam light pattern can be divided into several light spot regions, and each light spot region corresponds to an LED unit 10. For example, light spot a is the light spot projected by LED unit 10a, light spot b is the light spot projected by LED unit 10b, light spot c is the light spot projected by LED unit 10c, and light spot d is the light spot projected by LED unit 10d. In one embodiment, the size of the array of LED units 10 of the present application in the first direction X is about 100 mm, and each LED unit 10 is about 10 mm. The horizontal size of the low beam light pattern and / or the high beam light pattern required by regulations is that when the distance between the LED unit 10 and the test white wall in the third direction Z is 25 meters, the horizontal size of the low beam light pattern and / or the high beam light pattern formed by the projection of the LED unit 10 meets 40,000 millimeters. Therefore, if the array of LED units 10 wants to form a large-size low beam light pattern and / or high beam light pattern, the light spots emitted by each LED unit 10 need to be spliced together to form a large-size light pattern. The headlamp module 100 of the present application arranges a plurality of LED units 10 in an array, and in at least some of the LED units 10, the optical axis of the LED 13 is offset from the optical axis of the lens 15, so that the light spots projected by the LED units 10 have different emission directions, and the light spots projected by each LED unit 10 are arranged in sequence and can also be spliced into a low beam light pattern and / or a high beam light pattern. In this way, the structural design of the LED units 10 in the headlamp module 100 of the present application can not only simplify the layout difficulty of the LED units 10, but also reduce the size of the headlamp module 100, which is beneficial to the miniaturization design of the headlamp module 100.

[0072] It can be understood that the present application can achieve any light pattern other than the low beam light pattern and / or the high beam light pattern through different permutations and combinations of the LED units 10, including but not limited to welcome lights, specified patterns, etc.

[0073] The LED unit 10 of the present application is formed by encapsulating an LED and a lens corresponding to the LED 13. A plurality of LED units 10 form a headlamp module 100. On the one hand, the LED unit 10 removes the light shielding plate structure, reducing the number of components of the LED unit 10 and the specific spacing required for the optical design of the light shielding plate, thereby reducing the size of the headlamp module. On the other hand, the offset between the optical axis of the LED in the LED unit 10 and the optical axis of the lens 15 enables different LED units 10 in the headlamp module 100 to project illumination spots with specific energy distribution characteristics. The illumination spots with different specific energy distribution characteristics can be spliced to form a low beam light pattern and / or a high beam light pattern, completing the mapping from a small-sized LED unit 10 to a large-sized light pattern, further reducing the size of the headlamp module 100 and optimizing the arrangement of the LED units 10. Further, since the number of components encapsulated in the LED unit 10 is small and the alignment relationship between the components is simple, the alignment difficulty between the encapsulated components of the LED unit 10 can be reduced, ensuring accurate encapsulation, and thus ensuring that the light pattern of the encapsulated headlamp module 100 meets the regulatory requirements of the national vehicle low beam light pattern and / or high beam light pattern.

[0074] In some embodiments, referring to Figure 2 and Figure 4 , in at least one LED unit 10 of the LED unit array, the LED 13 and the lens 15 are coaxial.

[0075] Specifically, the fact that the LED 13 and the lens 15 are coaxial means that the projection center of the LED unit 10 in the XY plane coincides with the projection center of the lens 15 in the XY plane. In some embodiments, for the LED unit 10 located at the center of the headlamp module 100, for example, the optical axis of the LED 13 in the LED unit 10e does not need to be offset compared with the optical axis of the lens 15, that is, the offset distance Δd in the LED unit 10e is 0. When the LED 13 in the LED unit 10 and the lens 15 are coaxial, the central axis of the light emitted by the LED unit 10 is perpendicular to the XY plane, which can meet the spot requirements of the light pattern center.

[0076] In some embodiments, referring to Figure 2 and Figure 5 , in at least one LED unit 10 of the LED unit array, the optical axis of the LED 13 is offset from the optical axis of the lens 15.

[0077] Specifically, when the optical axis of the LED 13 is offset from the optical axis of the lens 15, the projection center of the LED 13 in the XY plane has a certain offset distance from the projection center of the lens 15 in the XY plane. This offset distance is Δd. In the same headlamp module 100, the offsets of the optical axes of the LED 13 and the lens 15 are not exactly the same. For example, Figure 2In the array of LED units 10, the distance h1 between the center of the LED unit 10a in the XY plane and the center O of the headlamp module 100 in the XY plane. The distance h2 between the center of the LED unit 10b in the XY plane and the center O (the exact center of the array) of the headlamp module 100 in the XY plane. Since h1 and h2 are of different magnitudes, the offset distances Δd of the LED 13 in the LED unit 10a and the LED unit 10b are different, being Δd1 and Δd2 respectively, where Δd1 > Δd2. In the same headlamp module 100, the different offset relationships between the optical axis of the LED 13 and the optical axis of the lens 15 enable the light spots of the LED unit 10 to be projected to different positions, and the light spots at different positions can be spliced into different light patterns to meet the requirements of the regulations for the low beam light pattern and / or the high beam light pattern.

[0078] In some embodiments, refer to Figures 2 to 6 , in the LED unit 10, the offset distance between the optical axis of the LED 13 and the optical axis of the lens 15 is positively correlated with the distance between the center of the optical axis of the LED unit 10 and the headlamp module 100.

[0079] Specifically, in each LED unit 10, the LED 13 and the lens 15 need to be offset in the direction perpendicular to the light-emitting optical path of the LED 13, so that the headlamp module 100 projects light spots at different positions, and then spliced into the required light pattern. In the low beam light pattern and / or the high beam light pattern, the light spots a, b, c, and d correspond to different positions in the XY plane. Therefore, in the LED units 10 that project the light spots a, b, c, and d, the offset distance Δd is different. Therefore, in the headlamp module 100, except for the LED unit 10 at the exact center O of the array of the LED units 10, the LED 13 in other LED units 10 needs to be offset in position with respect to the lens 15. Figure 6 In, the light spots e, f, g, and h are the centers of the light pattern, and the corresponding LED units 10 are also at the exact center O of the LED unit array. Therefore, in the LED units 10 that project the light spots e, f, g, and h, the LED 13 does not need to be offset, and the offset distance Δd is designed to be 0. It can be understood that in different light patterns, the number of LED units 10 located at the center is not the same. In Figure 6 , there are 4 LED units 10 whose LED 13 does not need to be offset with respect to the lens 15. In other embodiments, the number is any natural number value. Further, the larger the offset distance Δd between the optical axis of the LED 13 and the optical axis of the lens 15 in the LED unit 10 that is farther away from the center O of the LED unit array, and the smaller the offset distance Δd between the optical axis of the LED 13 and the optical axis of the lens 15 in the LED unit 10 that is closer to the center O of the LED unit array. For example, Figure 2In the XY plane, the distance between the center of the LED unit 10a and the center O of the LED unit array is h1, the distance between the LED unit 10b and the center O of the LED unit array is h2, h1 > h2, and Δd1 > Δd2.

[0080] The offset distance between the optical axis of the LED 13 and the optical axis of the lens 15 is positively correlated with the distance between the LED unit 10 and the optical axis center of the headlight module 100. This can ensure that when the LED units 10 at different positions project light spots, the light spots are evenly and effectively distributed in a predetermined area according to a certain rule. The regular distribution of the light spots helps to form a continuous and uniform lighting effect, avoiding the situation of local overbrightness or overdarkness. The positively correlated offset distance relationship enables the small-sized LED unit 10 to project and splice into a large-sized light pattern light spot by adjusting the offset distance between the LED 13 and the lens 15, so that the headlight module 100 can reduce its size. At the same time, it simplifies the design variables of the LED unit 10 in the headlight module 100, reduces the time for calculating the light spots of each LED unit 10 to map the light pattern one by one, reduces the design complexity of the headlight module 100, makes the packaging of the LED unit 10 and the headlight module 100 regular, and reduces the packaging difficulty.

[0081] In some embodiments, please refer to Figure 2 , Figure 5 , Figure 6 and Figure 7 , the LED 13 is located on the focal plane S of the lens 15. The offset distance Δd between the optical axis of the LED 13 and the optical axis of the lens 15 includes a first distance w along the first direction X and a second distance u along the second direction Y ( Figure 5 only the first distance w in the first direction X is shown). The first distance w is related to the effective focal length f of the lens 15 and the angle h of the light spot projected by the LED unit 10 in the first direction X. The second distance u is related to the effective focal length f of the lens 15 and the angle v of the light spot projected by the LED unit 10 in the second direction Y. Among them, -35° < h < 35°, -10° < v < 0°.

[0082] Specifically, please refer to Figure 2 , Figure 6 and Figure 7 . The focal plane S of the lens 15 is a plane perpendicular to the axis of the lens 15. On the focal plane S, the light rays refracted by the lens 15 will converge into a point, and this point is the effective focal length f. The focal plane S is located in the XY plane. Please refer to Figure 2, the offset distance Δd between the optical axis of LED13 and the optical axis of the lens 15 can be decomposed into a first distance w and a second distance u in the first direction X and the second direction Y respectively. The low beam light pattern and / or the high beam light pattern need to meet the requirements that when the distance between the headlamp module 100 and the test white wall is 25 meters, the angle h of the low beam light pattern and / or the high beam light pattern in the first direction X satisfies -35° < h < 35°, and the angle of the low beam light pattern and / or the high beam light pattern in the second direction Y satisfies -10° < v < 0°. Taking the calculation of the first distance w as an example. In this application, α(h, v) represents the light spot projected by an LED unit 10 at a corresponding angle. The position of the light spot in the first direction X is the angle h, and the position in the second direction Y is the angle v. The illuminance of the light spot projected by LED13 onto the test white wall is E, and the required illuminance by the regulations is El, then the minimum number m of LED13s required satisfies: m = El / E + 1.

[0083] Among them, the offset distance Δd of LED13 in the LED unit 10 satisfies Δd 2 = w 2 + u 2 . Since the size of LED13 is small, the size of LED13 can be ignored in the calculation. For the first distance w, the relationship between the first distance w and the effective focal length f of the lens 15 satisfies w = f * tan(h), where h represents the deflection angle of the light spot projected by LED13 in the first direction X. For the second distance u, the relationship between the second distance u and the effective focal length f of the lens 15 satisfies u = f * tan(v), where v represents the deflection angle of the light spot projected by LED13 in the second direction Y.

[0084] The mapping relationship between the first distance w and the effective focal length f of the lens 15 and the angle h of the light spot projected by the LED unit 10 in the first direction X, and between the second distance u and the effective focal length f of the lens 15 and the angle v of the light spot projected by the LED unit 10 in the second direction Y is specifically w = f * tan(h), u = f * tan(v). In this way, the offset of the light spot can be calculated through the first distance w and the second distance u, and the first distance w and the second distance u can also be calculated based on the offset of the light spot, so as to obtain the offset distance Δd of the optical axis of LED13 relative to the optical axis of the lens 15. The mapping relationship enables the headlamp module 100 to accurately calculate the offset distance Δd of the optical axis of LED13 relative to the optical axis of the lens 15 when packaging the LED unit 10, so that different LED units 10 can accurately project light spots at different positions.

[0085] In some embodiments, please refer to Figure 8 , in each LED unit 10, the number of LED13s is one or more. Each LED13 can be independently controlled so that the LED unit 10 can project light spots of different light patterns.

[0086] Specifically, in an LED unit 10, the number of LEDs 13 can be one or more. Each LED 13 is independently controlled by a switch. The switch can control the on / off and brightness of the LED 13. It can be understood that the arrangement of multiple LEDs 13 can also be diverse. The spacing between different LEDs 13 can be different, the edges of the outer contour of the LED unit 10 composed of multiple LEDs 13 can be aligned or misaligned, and the sizes of different LEDs 13 can be different. The switch includes but is not limited to a simple physical switch, an adjustment knob, an electronic controller, or an intelligent system. The LED unit 10 can control the on / off and brightness of multiple LEDs 13, thereby projecting light spots of different light patterns. For example, Figure 8 FIG. 3 shows three light spots projected by an LED unit 10 having four LEDs 13 under three control logics. Light spot (a) shows the light pattern when all four LEDs 13 emit light and the luminous intensities (brightness) of all four LEDs 13 are the same; light spot (b) shows the light pattern when one LED 13 does not emit light, and the other three LEDs 13 emit light and the luminous intensities (brightness) of these three LEDs 13 are the same; light spot (c) shows the light pattern when all four LEDs 13 emit light, but the luminous intensities (the first luminous intensity) of the two left LEDs 13 are the same, the luminous intensities (the second luminous intensity) of the two right LEDs 13 are the same, and the first luminous intensity is greater than the second luminous intensity. On the one hand, since the volume requirements of the headlight modules 100 of different vehicles are different, and the corresponding number of LED units 10 is also different, then, the number of LEDs 13 in the LED unit 10 can be arbitrarily designed to be able to adapt to the headlight modules 100 with different volume requirements. On the other hand, in some other embodiments of the present application, the switch can also control the frequency and color of the LED 13 to achieve a richer headlight lighting effect. For example, the driver can adjust the frequency and color of the LED light according to different driving environments and conditions, including using warm white light when driving on urban roads, switching to cold white light when driving on highways to improve line of sight clarity, or using yellow light when encountering low visibility conditions such as foggy days to improve the visibility of the vehicle 1000.

[0087] The LED unit 10 of the present application can change the brightness and on / off of different LEDs 13 in the unit. The light spot in a single LED unit 10 can also achieve different shape and brightness combinations, just like the near-light light pattern and / or the far-light light pattern formed by splicing the light spots projected by the LED unit array (i.e., the light spots projected by the headlight module 100).

[0088] Specifically, in the LED unit 10, the LED 13 is disposed on the focal plane S of the lens 15, that is, the distance L from the LED 13 to the lens 15 is determined. Since the light-emitting part of the LED 13 is not a point but a light-emitting surface with a certain area, the light-emitting angle θ is related to both the diameter of the LED 13 and the diameter D of the lens 15. It can be understood that since the diameter of the LED 13 is smaller than the diameter of the lens 15, the diameter of the LED unit 10 mainly depends on the diameter D of the lens 15. Therefore, if the diameter of the LED unit 10 is to be reduced, the diameter D of the lens 15 needs to be decreased. However, the LED 13 is a Lambertian light source, and the brightness on the surface of the LED 13 appears to be the same. Therefore, the smaller the diameter D of the lens 15, the less light emitted by the LED 13 passes through, which will affect the brightness of the headlight module 100. Further, whether the brightness of the headlight module 100 can meet the standard is related to conditions such as the efficiency of the LED unit 10, the light-emitting efficiency of the LED 13, the luminous flux of the LED, and the light-emitting area of the LED 13 (i.e., the number of the LED 13s). In different embodiments, the brightness of the headlight module 100 can be made to meet the requirements by adjusting at least one of the efficiency of the LED unit 10, the light-emitting efficiency of the LED 13, the luminous flux of the LED, and the light-emitting area of the LED 13 (i.e., the number of the LED 13s).

[0089] In some embodiments, referring to Figure 4 , the lens 15 includes an incident light surface 151 and an exit light surface 153 that face away from each other, and the incident light surface 151 is closer to the LED 13 than the exit light surface 153. In one example, the incident light surface 151 is a plane, an aspherical surface, or a free-form surface. In another example, the exit light surface 153 is a plane, an aspherical surface, or a free-form surface. In still another example, the incident light surface 151 is a plane, an aspherical surface, or a free-form surface, and the exit light surface 153 is a plane, an aspherical surface, or a free-form surface.

[0090] Specifically, the incident light surface 151 and the exit light surface 153 can be combined differently according to the requirements of different headlight modules 100 and can be different curved surface forms respectively. For example, when the incident light surface 151 is a plane, the exit light surface 153 is a free-form surface; when the incident light surface 151 is an aspherical surface, the exit light surface 153 is a free-form surface; when the incident light surface 151 is a free-form surface, the exit light surface 153 is a plane, and other arbitrary permutations and combinations are not listed one by one here.

[0091] The incident light surface 151 and the exit light surface 153 adopt different curved surfaces, which can endow a single lens 15 with different and more optical characteristics. For example, when shaping the light beam emitted by the LED 13 with a single lens 15, various optical aberrations such as spherical aberration also need to be corrected. The use of different curved surfaces for the incident light surface 151 and the exit light surface 153 can enable the aberrations that originally required the combination of multiple lenses 15 to be corrected with fewer or smaller lenses 15, thereby reducing the volume and quantity of the entire LED unit 10.

[0092] Please refer to Figure 4 、 Figure 5 、 Figure 10 or Figure 11 , in some embodiments, the lens 15 is a single microlens.

[0093] Specifically, an LED unit 10 contains only one lens, and this lens is a microlens. On the one hand, since the LED unit 10 contains only one lens, the encapsulation is simple, which is beneficial to the fabrication of the LED module 100. On the other hand, the use of a microlens can achieve a miniaturized design of the LED unit 10, and further reduce the size of the headlamp module 100.

[0094] Please refer to Figure 9 , in some other embodiments, the lens 15 includes multiple lenses, and the multiple lenses 15 are arranged in sequence along the light-emitting direction of the LED 13.

[0095] For Figure 9Taking the LED unit 10 shown as an example, the LED unit 10 includes three microlenses 15. The three lenses 15 are arranged in sequence along the light-emitting direction of the LED 13, and adjacent lenses 15 are spaced apart from each other. In other embodiments, the number of lenses 15 is not limited, and it can be 2, or 4, 5, 6 or more. The inclusion of multiple lenses 15 in one LED unit 10 can, on the one hand, more precisely control the direction of the light emitted by the LED 13, achieve precise focusing and distribution of the emitted light, obtain a light spot that meets the requirements, and further obtain a low beam light pattern and / or high beam light pattern that meet the requirements. On the other hand, the multiple lenses 15 can optimize the propagation path of the light emitted by the LED 13, reduce light loss and reflection, make the light emitted by the LED unit 10 more concentrated and bright, and improve the lighting effect. On the further hand, the multiple lenses 15 are arranged in sequence along the light-emitting direction of the LED 13, without increasing the diameter of the LED unit 10, which can ensure the small size of the LED unit 10. The sequential arrangement of the multiple lenses 15 is regular and does not increase the packaging difficulty of the LED unit. On still another hand, compared with the existing LED unit with a direct-through structure, although the LED unit 10 of this embodiment also has a direct-through structure, the light-shielding plate is removed, the number of components of the LED unit 10 is streamlined, and the size of the headlight module 100 is further reduced. Among them, the direct-through scheme refers to a design method of a headlight module, in which each LED unit no longer requires a separate reflector, but directly shapes the light of the LED through a lens and a light-shielding plate to form a required illuminated area. And, the LED unit 10 including multiple lenses 15 in this embodiment not only further adjusts the arrangement manner of the multiple lenses 15, but regards the LED 13 and the lenses 15 as an LED unit 10. A number of LED units 10 can be independently arranged, but the arrangement position and the arrangement manner of the LED 13 and the lenses 15 inside the LED need to be adjusted.

[0096] Please refer to Figure 4 , Figure 5 , Figure 9 , Figure 10 or Figure 11 , in some embodiments, the LED unit 10 further includes a support member 17. The support member 17 is formed with a receiving cavity 171. The LED 13 is received in the receiving cavity 171. The lens 15 is supported on the support member 17.

[0097] Specifically, in the LED unit 10, the support member 17 is an element for supporting the lens 15. The support member 17 can be sealed or non-sealed. The lens 15 is supported on the support member 17, which can ensure that the position of the lens 15 does not change, making it easier to align with the LED 13 and facilitating the assembly of the LED unit 10. The accommodation cavity 171 is a cavity structure formed by the support member 17, which provides an installation space for the LED 13 to ensure that the LED 13 can maintain the correct position and orientation under various working conditions, reducing the risk of displacement or damage caused by vibration or other mechanical stresses, improving the structural stability of the headlight module 100, and extending the service life of the LED 13. During the encapsulation process, the accommodation cavity 171 simplifies the positioning of the LED 13 and the lens 15, enabling the LED unit 10 in the headlight module 10 to project light spots at different positions, thereby splicing and making the encapsulation of the headlight module 10 more efficient and precise.

[0098] In some embodiments, please refer to Figure 4 , Figure 5 or Figure 9 , the support member 17 includes a support body 173 and an extension portion 175. The support body 173 encloses the accommodation cavity 171 and is carried on the substrate 11. The extension portion 175 extends from the inner wall of the support body 173 towards the center of the accommodation cavity 171. The lens 15 is supported on the extension portion 175.

[0099] Specifically, please combine with Figure 13, the receiving cavity 171 is used to accommodate and protect the LED 13 to ensure the accurate position of the LED 13 in the LED unit 10. The extending portion 175 is an element extending from the inner wall of the supporting body 173 towards the center of the receiving cavity 171 and is used to support the lens 15. In one example, the extending portion 175 and the supporting body 173 are integrally formed. In some other examples, the extending portion 175 may not be integrally formed with the supporting body 173, but rather the extending portion 175 and the supporting body 173 are two separate elements, and the two are detachably connected together to form the support member 17. The ways of detachable connection include but are not limited to snap connection, threaded connection, and the combination of the two. The detachable extending portion 175 can make the setting of the LED unit 10 more flexible and is beneficial for maintenance. The extending portion 175 can be made of a material with a certain elasticity, including but not limited to rubber, plastic, or styrene, etc. The extending portion 175 can also be covered with an elastic material on the surface of the extending portion 175 alone after being integrally formed with the supporting body 173. At this time, the extending portion 175 with a certain elasticity can not only provide support for the lens 15, but also provide a certain shock absorption effect for the lens 15 to prevent the lens 15 from separating from the LED unit 10 when the vehicle 1000 travels on a bumpy road section. The extending portion 175 provides a stable support point for the lens 15 to ensure that the lens 15 can allow the light emitted from the LED 13 aligned with it to pass through to the greatest extent, ensuring the correct propagation of light and beam shaping. At the same time, the setting of the extending portion 175 reduces the positioning and fixing steps when installing the lens 15, thereby reducing the alignment and adjustment time and reducing the complexity of the encapsulation of the headlight module 100.

[0100] In some other embodiments, please refer to Figure 10 , the support member 17 includes a bottom wall 177 and a side wall 178. The bottom wall 177 and the side wall 178 enclose the receiving cavity 171. The base 11 is carried on the bottom wall 177 and is located within the receiving cavity 171. The lens 15 is supported on the top of the side wall 178.

[0101] Specifically, please refer to Figure 10, the side wall 178 of the support member 17 extends upwardly around the bottom wall 177 and together with the bottom wall 177 defines a receiving cavity 171. The base 11 is mounted on the bottom wall 177 and is located within the receiving cavity 171. The base 11 is in close contact with the LED 13 and can effectively conduct the heat generated when the LED 13 operates. The lens 15 is directly supported on the top of the side wall 178. On the one hand, the number of fixing points between the lens 15 and the side wall 178 is reduced, simplifying the encapsulation of the LED unit 10, and thus reducing the encapsulation difficulty of the headlight module 100. On the other hand, the lens 15 is directly supported on the top of the side wall 178, enabling the lens 15 to receive the light emitted by the LED 13 at the maximum angle, ensuring that there is no obstruction in the light propagation path, maximizing the angular adjustment space of the lens 15, thereby saving the diameter of the lens 15, optimizing the lighting effect of the LED unit 10, and reducing the size of the headlight module 100.

[0102] In still some embodiments, please refer to Figure 11 , the support member 17 is an optical adhesive 179. The bottom of the optical adhesive 179 bears on the base 11. The lens 15 is supported on the top of the optical adhesive 179. The optical adhesive 179 is filled between the base 11 and the lens 15.

[0103] Specifically, please refer to Figure 11 and Figure 13。The optical adhesive 179 is a material with high transparency and a specific refractive index, capable of connecting or fixing components. In this application, the optical adhesive 179 is a material with high temperature resistance, low absorption rate for the light source band, and good stability, and can be a colloid that solidifies from a liquid state. The optical adhesive 179 includes but is not limited to silicone-based optical adhesives, acrylic-based optical adhesives, epoxy resin-based optical adhesives, or optically transparent acrylic adhesives, etc. The bottom of the optical adhesive 179 is carried on the substrate 11, and the lens 15 is supported on the top of the optical adhesive 179. When the LED unit 10 is encapsulated, the optical adhesive 179 is in a liquid state initially. After the optical adhesive 179 covers the LED 13, the lens 15 is placed on the optical adhesive 179. During the curing process, the optical adhesive 179 directly adheres to the substrate 11, the LED 13, and the lens 15. Further, considering that during the long-term adhesion process, the lens 15 may shift in position relative to the LED 15, the encapsulation method can be to first fix the LED 13 and the lens 15 with a small amount of quick-drying adhesive, and then fill and cure with the optical adhesive 179. The optical adhesive 179 as the support member 17 not only provides good mechanical stability, but also brings additional benefits due to the material properties of the optical adhesive 179. First, the optical adhesive 179 has good light transmittance, ensuring that light does not scatter or lose when passing through, and guaranteeing the efficiency of light propagation. Second, the optical adhesive 179 has good weather resistance and temperature resistance, and can maintain stable performance even under extreme temperatures or harsh environments, thereby protecting the lens 15 and the LED 13 from damage. In addition, the flexibility of the optical adhesive 179 can absorb and reduce vibrations and impacts generated during the driving of the vehicle 1000, which helps to extend the service life of the LED unit 10. Finally, the use of the optical adhesive 179 also reduces the air gap between components, reduces the optical distortion caused by the air gap, and ensures the precise focusing of light and high-quality lighting effects. Therefore, using the optical adhesive 179 as the support member 17 in the LED unit 10 in this embodiment not only simplifies the encapsulation, but also improves the optical performance and reliability of the LED unit 10.

[0104] In some embodiments, referring to Figure 12 , the LED unit 10 further includes a reflector bowl structure 19 disposed on the substrate 11. The reflector bowl structure 19 is provided with a reflecting cavity 191. The LED 13 is located within the reflecting cavity 191. The inner wall of the reflecting cavity 191 is provided with a reflecting layer 1911. The reflecting layer 1911 is used to reflect the light emitted by the LED 13 to the lens 15.

[0105] Specifically, the reflecting bowl structure 19 collects and redirects light through the internal bowl-shaped reflecting cavity 191 to concentrate the light emitted by the LED 13 in one direction. The reflecting bowl structure 19 can be made of various materials, including but not limited to glass or colloid, etc. The cross-sectional shape of the reflecting bowl structure 19 is not restricted and can be a cuboid, a cylinder, a frustum of a cone, or an irregular shape, as long as a bowl-shaped reflecting cavity 191 can be constructed inside the reflecting bowl structure 19. The bottom of the reflecting bowl structure 19 is a plane with a certain area, and the top area is larger than the bottom area. The reflecting bowl structure 19 and the base 11 can be fixed by various methods such as gluing or clamping. The reflecting bowl structure 19 can reduce the scattering of light, making the light more concentrated, thereby improving the brightness and efficiency of lighting. The reflecting layer 1911 in the reflecting cavity 191 can reflect the light emitted by the LED 13 to ensure that the light propagates in a predetermined direction. The materials of the reflecting layer 1911 include but are not limited to aluminum materials, polycarbonate, or polymethyl methacrylate, etc. The LED unit 10 of the present application can precisely control the light pattern by adjusting the shape and position of the reflecting layer 1911 to meet specific lighting requirements. It should be noted that the reflecting cavity 191 can be partially covered with the reflecting layer 1911 or completely covered with the reflecting layer 1911.

[0106] Please refer to Figure 13 , the embodiment of the present application also provides a vehicle 1000, and the vehicle 1000 includes the headlight module 100 of any one of the above embodiments.

[0107] Specifically, please combine Figure 5 , the LED unit 10 in the headlight module 100 is formed by encapsulating an LED and a lens corresponding to the LED 13. A plurality of LED units 10 form the headlight module 100. On the one hand, the LED unit 10 removes the light shielding plate structure, reduces the number of components of the LED unit 10 and the specific spacing required for the optical design of the light shielding plate, thereby reducing the size of the headlight module. On the other hand, the offset between the optical axis of the LED in the LED unit 10 and the optical axis of the lens 15 enables different LED units 10 in the headlight module 100 to project illumination spots with specific energy distribution characteristics. The illumination spots with different specific energy distribution characteristics can be spliced to form a low beam light pattern and / or a high beam light pattern, completing the mapping from small-sized LED units 10 to a large-sized light pattern, further reducing the size of the headlight module 100 and optimizing the arrangement method of the LED units 10. Further, since the number of components encapsulated in the LED unit 10 is small and the alignment relationship between the components is simple, the alignment difficulty between the encapsulated components of the LED unit 10 can be reduced, and accurate encapsulation can be ensured.

[0108] Although embodiments of the present application have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to the embodiments of the present application without departing from the principles and spirit of the present application. The scope of the present application is defined by the claims and their equivalents.

Claims

1. An LED unit for a vehicle headlamp module, characterized in that: The LED unit comprises: LED, the LED is used to emit light; and A lens, wherein the lens is arranged on the light path of the LED, the LED is located on the focal plane of the lens, and the lens performs beam shaping on the light emitted by the LED to form an illumination spot; Wherein, when the optical axis of the LED is offset from the optical axis of the lens, the offset distance between the optical axis of the LED and the optical axis of the lens is positively correlated with the distance between the optical axis centers of the LED unit and the headlamp module.

2. The LED unit according to claim 1, characterized in that: The offset distance between the optical axis of the LED and the optical axis of the lens includes a first distance along a first direction and a second distance along a second direction, wherein the first distance is related to the effective focal length f of the lens and the angle h of the light spot projected by the LED unit in the first direction, and the second distance is related to the effective focal length f of the lens and the angle v of the light spot projected by the LED unit in the second direction, wherein -35° <h<35°,-10°<v<0°。 3. The LED unit according to claim 1, characterized in that: The number of the LED is one; or, There are multiple LEDs, and each LED can be independently controlled so that the LED unit can project light spots of different light types.

4. The LED unit according to claim 1, characterized in that: The lens comprises a light incident surface and a light emitting surface which are opposite to each other, and the light incident surface is closer to the LED than the light emitting surface; The light incident surface is a plane, an aspherical surface or a free-form surface; and / or The light emitting surface is a spherical surface, an aspherical surface or a free-form surface.

5. The LED unit according to claim 1, characterized in that: The lens is a single microlens; or The lenses include a plurality of lenses, which are arranged in sequence along the light emitting direction of the LED.

6. The LED unit according to claim 1, characterized in that: The LED unit further comprises: A support member is formed with a receiving cavity, the LED is received in the receiving cavity, and the lens is supported on the support member.

7. The LED unit according to claim 6, characterized in that: The LED unit further comprises a base, the support member comprises a support body and an extension portion, the support body encloses the accommodating cavity and is supported on the base, the extension portion extends from the inner wall of the support body toward the center of the accommodating cavity, and the lens is supported on the extension portion; or The support member comprises a bottom wall and a side wall, the bottom wall and the side wall enclose the accommodating cavity, the substrate is carried on the bottom wall and located in the accommodating cavity, and the lens is supported on the top of the side wall; or The supporting member is an optical glue, the bottom of the optical glue is supported on the base, the lens is supported on the top of the optical glue, and the optical glue is filled between the base and the lens.

8. The LED unit according to claim 1, characterized in that: The LED unit further comprises: substrate; and A reflective bowl structure is arranged on the base, the reflective bowl structure is provided with a reflective cavity, the LED is located in the reflective cavity, the inner wall of the reflective cavity is provided with a reflective layer, and the reflective layer is used to reflect the light emitted by the LED to the lens.

9. The LED unit according to any one of claims 1 to 8, characterized in that: The illumination light spot is configured as a low beam light type and / or a high beam light type.

10. A headlamp module, characterized in that: include: The LED unit according to any one of claims 1 to 9.

11. A headlamp module, characterized in that: include: A plurality of LED units, each of which comprises a substrate, an LED and a lens, wherein the LED is mounted on the substrate and electrically connected to the substrate, and the LED is used to emit light; the lens assembly is arranged on the light path of the LED; wherein: A plurality of the LED units are distributed in an array, and in at least some of the LED units, the optical axis of the LED is offset from the optical axis of the lens so that the LED unit emits light to form an illumination spot. In the LED unit, the offset distance between the optical axis of the LED and the optical axis of the lens is positively correlated with the distance between the LED unit and the optical axis center of the headlight module.

12. The headlamp module according to claim 11, characterized in that: The LED is located on the focal plane of the lens, and the offset distance between the optical axis of the LED and the optical axis of the lens includes a first distance along a first direction and a second distance along a second direction, wherein the first distance is related to the effective focal length f of the lens and the angle h of the light spot projected by the LED unit in the first direction, and the second distance is related to the effective focal length f of the lens and the angle v of the light spot projected by the LED unit in the second direction, wherein -35° <h<35°,-10°<v<0°。 13. The headlamp module according to claim 11, characterized in that: The number of the LED is one; or There are multiple LEDs, and each LED can be independently controlled so that the LED unit can project light spots of different light types.

14. The headlamp module according to claim 11, characterized in that: The lens comprises a light incident surface and a light emitting surface which are opposite to each other, and the light incident surface is closer to the LED than the light emitting surface; The light incident surface is a plane, an aspherical surface or a free-form surface; and / or The light emitting surface is a spherical surface, an aspherical surface or a free-form surface.

15. The headlamp module according to claim 11, characterized in that: The lens is a single microlens; or The lenses include a plurality of lenses, which are arranged in sequence along the light emitting direction of the LED.

16. The headlamp module according to claim 11, characterized in that: The LED unit further comprises: A support member is formed with a receiving cavity, the LED is received in the receiving cavity, and the lens is supported on the support member.

17. The headlamp module according to claim 16, characterized in that: The support member includes a support body and an extension portion, the support body encloses the accommodating cavity and is supported by the base, the extension portion extends from the inner wall of the support body toward the center of the accommodating cavity, and the lens is supported on the extension portion; or The support member comprises a bottom wall and a side wall, the bottom wall and the side wall enclose the accommodating cavity, the substrate is carried on the bottom wall and located in the accommodating cavity, and the lens is supported on the top of the side wall; or The supporting member is an optical glue, the bottom of the optical glue is supported on the base, the lens is supported on the top of the optical glue, and the optical glue is filled between the base and the lens.

18. The headlamp module according to claim 11, characterized in that: The LED unit further comprises: A reflective bowl structure is arranged on the base, the reflective bowl structure is provided with a reflective cavity, the LED is located in the reflective cavity, the inner wall of the reflective cavity is provided with a reflective layer, and the reflective layer is used to reflect the light emitted by the LED to the lens.

19. The headlamp module according to any one of claims 11 to 18, characterized in that: The illumination light spot is configured as a low beam light type and / or a high beam light type.

20. A vehicle, characterized in that: A headlamp module comprising any one of claims 10-19; or an LED unit comprising any one of claims 1-10.

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