Headlight module of a vehicle headlight, vehicle headlight and vehicle possessing the vehicle headlight

Description

[0001] The present disclosure relates generally to a headlight module. In particular, the present disclosure relates to a headlight module of a vehicle headlight, a vehicle headlight, and a vehicle comprising the vehicle headlight.

[0002] From EP 3 524 881 A1, a vehicle headlight with a projection lens and a light source arranged behind the projection lens is known. The projection lens is movable relative to the light source, so that the position of maximum luminous intensity of a light distribution pattern formed by the projection lens can be changed.

[0003] US Patent 2011 / 205748 concerns a vehicle headlight with a multi-focal-length lens and a light source, which can be switched between a high beam mode and a low beam mode by means of a movable lens. The multi-focal-length lens allows the high and low beam distribution to be individually shaped.

[0004] Furthermore, EP 2 910 848 A1 describes a vehicle headlight with a lens arranged in front of a semiconductor light source. The lens has several lens sections for generating different light focusing and scattering patterns.

[0005] WO2020 / 156455 A1 discloses a vehicle headlight comprising an LED light source and optical elements for high beam and low beam.

[0006] Furthermore, LED (Light Emitting Diode) matrix headlights with headlight modules are also known, which are designed to provide various headlight functions. For example, a headlight module can be designed to provide a high beam function. In so-called HD (High Definition) headlights, a headlight module can be designed to project patterns, such as symbols and / or directional signs, onto the road, thus providing the driver with useful information. The headlight resolution can generally be increased by reducing the illumination area per pixel, but this can lead to a restriction of the overall projection area of ​​the headlight.

[0007] One objective of the embodiments of the present disclosure is to provide a headlight module which makes it possible to provide a headlight with a high headlight resolution and a large projection area.

[0008] To solve this task, after considering a first aspect, a headlight module of a vehicle headlight is provided to generate a headlight beam with a high beam projection area or projection field and with a low beam projection area or projection field.

[0009] The headlight module comprises an LED module, which in turn includes an LED pixel array with a number of LED pixels, each emitting a single LED light source. The LEDs can be arranged in a matrix or pixel configuration, particularly on one or more substrates, especially metal core circuit boards. The LED pixel array has a sufficient number or packing density of LED pixels to achieve the high-definition (HD) functionality of the headlight. The individual LEDs or LED pixels of the LED module can be controlled separately and independently.

[0010] The headlight module further comprises a headlight optic with an optical element arranged within a housing between the LED module and a light exit window, the light exit window (5) being configured as a converging and / or diverging lens. The housing is essentially axially symmetrical about an axis of symmetry, the axis of symmetry coinciding with a main emission direction of the headlight module. The optical element is configured to shape the respective LED light into a partial light beam for illuminating a partial area of ​​the high beam projection area and / or the low beam projection area. The optical element is further configured such that the high beam projection area can be illuminated by a first group of partial light beams and the low beam projection area by a second group of partial light beams.

[0011] According to the invention, the optical element is designed as a freeform lens and serves to extend a projection area of ​​partial light rays.

[0012] According to the invention, the freeform lens is arranged in the housing above the axis of symmetry, and is preferably designed as part of a lens system, and the freeform lens is designed such that the projection areas of the first group of partial light rays are widened in a vertical direction.

[0013] According to the invention, the freeform lens is designed such that the partial light rays of the first group have a horizontal opening angle of approximately 0.1° or less and a vertical opening angle of approximately 0.2° or more. The partial light rays of the second group have an opening angle of approximately 0.1° or less in both the vertical and horizontal directions.

[0014] By widening the projection areas of the first group of partial light beams, the headlight beam distribution can be selectively modified in certain areas. In particular, the overall high beam projection area can be enlarged without affecting the illumination of the near beam projection area or the headlight resolution within that area.

[0015] The spotlight module thus enables the targeted widening of those projection areas where the spotlight resolution, particularly in the beam expansion direction, is less critical. This expands the application possibilities of the LED matrix spotlights. The overall spotlight beam can be widened, ensuring that high resolution is maintained in those projection areas where resolution is critical, for example, due to HD functionality.

[0016] In particular, the freeform lens can be designed such that an extension of the projection area is achieved in the high-beam projection range of the headlight, albeit at the cost of a reduction in resolution, while the headlight resolution in the near-beam projection range is not affected or only minimally affected. Thus, a high resolution can be maintained in the near-beam projection range, allowing the HD functionality of the headlight to be fully realized in this range.

[0017] The freeform lens can be designed such that the high beam projection area and the near beam projection area touch and / or partially overlap. Because the high beam projection area and the near beam projection area touch or overlap, the driver's field of view (FOV) in the central area is well illuminated, resulting in a smooth transition between the high beam and near beam projection areas without any dark zones.

[0018] The freeform lens can be configured, in particular, to extend the high beam projection area over a vertical angular range of -4° to +6°, especially -2° to +3°, relative to the horizontal plane. With this vertical opening angle of -4° to +6°, especially -2° to +3°, of the high beam projection area, the entire projection area of ​​the high beam can be covered without the use of additional light-directing elements, such as DMDs (Digital Mirror Devices) or other mechanically adjustable elements.

[0019] The freeform lens can further be configured such that the near-beam projection area extends over a vertical angular range of -10° to 0°, in particular -8° to -1°, relative to the horizontal plane. This angular range of -10° to 0°, in particular -8° to -1°, essentially covers the entire near-beam projection area for HD functionality, especially for providing high-resolution driver assistance projections onto the road. Thus, a single headlight module can essentially cover both the high-beam and HD functionality without any loss of luminous efficacy at the edges of the illumination field, particularly at the upper and lower edges of the high-beam and near-beam projection areas, respectively.

[0020] In some embodiments, the freeform lens is designed such that the extension of the projection areas of the first group of partial light rays can essentially only occur in the vertical direction. When implementing the so-called glare-free high beam or adaptive driving beam, or glare-free high beam with adaptive dimming function, the vertical resolution of the headlight beam is generally less critical, so the projection area can be extended vertically without noticeably impairing headlight performance. The adaptive driving beam or glare-free high beam can, if necessary, be achieved by masking segments from the high beam with high horizontal resolution.

[0021] The freeform lens can be designed such that the partial light rays of the first group have a horizontal opening angle of approximately 0.1° or less and a vertical opening angle of approximately 0.2° or more. Due to the larger vertical opening angles, the vertical projection area of ​​the partial light rays, and thus of the high beam headlights, can be increased while maintaining high horizontal resolution.

[0022] The freeform lens can be designed such that the partial light beams of the second group have an opening angle of approximately 0.1° or less in both the vertical and horizontal directions. This headlight resolution makes it possible to project symbols and / or directional signs onto the road in such a way that they are clearly visible to the driver. Thus, the two functions can be implemented in a single headlight module: high-definition projection for driver assistance with a projection area directly in front of the vehicle, up to a distance of approximately 7 m, and high beam function with a vertical projection angle of approximately 3° above the horizontal plane.

[0023] The freeform lens can be designed such that it is essentially only captured by the first group of partial beams. In particular, the freeform lens can be designed as an add-on element for retrofitting existing headlight modules. By using this optical element, the illumination range of headlights can be easily extended by retrofitting existing headlight modules.

[0024] According to a second aspect, a vehicle headlight is provided to generate a headlight beam with a high beam projection area and a low beam projection area. The vehicle headlight has at least one headlight module according to the first aspect. The headlight provides full functionality in both the high beam and low beam projection areas and has a particularly simple design, as both functionalities of the headlight can be implemented with a single headlight module.

[0025] Following a third aspect, a vehicle is provided with a headlight as described in the second aspect. The vehicle offers full headlight functionality and can be manufactured cost-effectively. Reducing the number of headlight modules makes the vehicle lighter overall and opens up further design freedom for vehicle designers.

[0026] The invention will now be explained in more detail with reference to the accompanying figures. The same reference numerals are used in the figures for identical or equivalently functioning parts. Fig. 1 shows a schematic cross-section of a headlight module according to an embodiment, Fig. 2 schematically shows an illumination field of a headlight according to an embodiment, and Fig. 3 shows an illumination pattern of an illumination field according to Fig. 2 .

[0027] Fig. 1 shows a schematic cross-section of a headlight module according to an exemplary embodiment. The view of the Fig. 1 This corresponds to a vertical cross-section of the headlight module 1 in its installed state. The headlight module 1 comprises a housing 2 with a first end 3 and a second end 4. At the first end 3 of the housing 2 there is a light emission window 5 and at the second end 3 of the housing 2 an LED module 6 with a number of LEDs (not shown) is arranged.

[0028] The headlight module 1 further comprises a headlight optic 7, which is arranged within the housing 2 between the LED module 6 and the light exit window 5. The housing 2 is essentially axially symmetrical with an axis of symmetry 8, the axis of symmetry 8 being essentially coincident with the main emission direction of the headlight module 1. The headlight optic 7 comprises an optical element 9, which is arranged asymmetrically within the housing 2, i.e., above the axis of symmetry 8. The light exit window 5 can, in particular, be configured as part of the headlight optic 7 or as an active optical element, especially as a converging and / or diverging lens.

[0029] Fig. 1 Figure 10 also shows a body part 10 of the vehicle as well as a fastening element 11 for attaching the headlight module 1 to the vehicle or within a headlight of the vehicle.

[0030] In this embodiment, the headlight module 1 is designed as an LED matrix headlight module, wherein the LEDs are arranged in a matrix within the LED module 6. In the illustrated embodiment, the headlight module 1 comprises a primary optic 12 for focusing the light emitted by the respective LEDs. The primary optic 12 can be designed as part of the LED module 6 or as a separate optical element.

[0031] The operation of the headlight module 1 is illustrated by schematically depicted limit light rays (shown as dashed lines) of the headlight beam. The light emitted by the LEDs of the LED module 6 is shaped by the headlight optics into the headlight beam, which exits through the light exit window 5. A first part of the headlight beam illuminates a first projection area 20, and a second part of the headlight beam illuminates a second projection area 30.

[0032] The alignment of headlight module 1 in Fig. 1 This corresponds to the orientation of the headlight module 1 in its installed state. The first projection area 20, or upper projection area, illuminates an upper part of the headlight illumination field, or high beam projection field, in a pixelated manner. The second projection area 30, or lower projection area 30, illuminates a lower part of the headlight illumination field, or low beam projection field, in a pixelated manner. The headlight pixels are generated by partial light beams of the headlight beam, which can be illuminated separately or independently of each other by controlling the individual LEDs of the LED module.

[0033] The headlight resolution is determined by the pixel size or the opening angles of the light cones of individual partial light rays, each illuminating a portion of the first projection area 20 or the second projection area 30. The first projection area 20 is illuminated by a first group of partial light rays, and the second projection area 30 is illuminated by a second group of partial light rays. The optical element 9 is designed to selectively widen the light cones or the projection areas of the partial light rays. In particular, the asymmetrical arrangement of the optical element 9, offset from the axis of symmetry, ensures that essentially only the partial light rays of the first group are widened in the vertical direction. The optical element 9 thus allows the projection area of ​​the headlight beam in the high beam range to be widened vertically.Optical element 9 can be designed, in particular, as an add-on element for retrofitting existing headlight modules. By using this optical element, the illumination range of headlights can be easily extended by retrofitting existing headlight modules.

[0034] As demonstrated using the limiting light rays in Fig. 1 As can be seen, the first projection area 20 and the second projection area 30 partially overlap in the vertical direction. Depending on the design, the overlap angle between the first projection area 20 and the second projection area 30 in the vertical direction can range from 2° to 5°. Due to the overlap of the first projection area 20 and the second projection area 30, the driver's field of vision is well illuminated in the central area, so that a smooth transition without a dark zone is created between the high beam projection area and the low beam projection area, even when the low beam function is activated.

[0035] Due to the vertical widening of the partial light rays of the first group, the vertical angular range of the first projection area 20, or of the entire high beam, can be widened, so that the first projection area 20 extends over a vertical angular range of -2° to +3° (relative to the horizontal plane). With the vertical opening angle of -2° to +3° of the first projection area 20, the entire projection area of ​​the high beam can be covered without the use of additional light-directing elements.

[0036] The headlight optics 7 can be designed such that the second projection area extends over a vertical angular range of -8° to -1°. The headlight module 1 can thus cover both the entire high beam range and the entire low beam range.

[0037] The optical element 9 is designed such that the headlight beam distribution in the horizontal direction is not affected or only minimally affected. In particular, the optical element 9 can be designed such that the widening of the projection areas of the first group of partial light rays occurs essentially only in the vertical direction. Thus, the optical element 9 does not affect the horizontal resolution of the partial light rays, or only minimally affects them, so that despite the widening of the partial light rays, a glare-free high beam headlight with high horizontal resolution can be achieved. The horizontal opening angle of the partial light rays of the first group as well as the second group of partial light rays can be approximately the same. In some embodiments, the horizontal opening angle of the partial light rays is approximately 0.1°.However, the vertical opening angle of the partial light rays of the first group can be greater than 0.1°, in particular about 0.2° or more, due to the widening by the optical element 9.

[0038] According to the invention, the optical element 9 is designed as a freeform lens. The freeform lens allows for targeted and precise adjustment of the beam guidance or the widening of the partial light beams. In some embodiments, the freeform lens is designed as part of a lens system that can be integrated into the headlight module 1.

[0039] Fig. 2 Figure 1 schematically shows an illumination field of a headlight according to an exemplary embodiment. In particular, it shows Fig. 2 The illumination field 50 of the headlight is shown schematically from the driver's perspective. The horizontal beam angle of the headlight beam, relative to a central point, is plotted on the X-axis. The vertical beam angle of the headlight beam, relative to the central point, is plotted on the Y-axis. The first projection area 20, or high beam projection area, extends horizontally approximately between -12° and +12° and vertically approximately between -2° and +5°. The second projection area 30, or low beam projection area, extends horizontally approximately between -10° and +10° and vertically approximately between -7° and -1°. The first projection area 20 and the second projection area 30 partially overlap, with a vertical overlap angle of approximately 1°. The vertical position of the X-axis corresponds to the horizon line.The portion of the illumination field below the X-axis corresponds to the near-beam projection area, in which HD functionality can be implemented. Specifically, symbols such as road signs can be projected onto the road in this near-beam projection area, thus conveying information to the driver.

[0040] Fig. 3 shows an illumination pattern of an illumination field according to Fig. 2 . That in Fig. 3 The illumination pattern shown results from a light simulation when the illumination field is illuminated with a headlight module according to Fig. 1The illuminated area is illuminated by the headlight. The illumination field 50 is illuminated in both the high beam projection area 20 and the low beam projection area 30. A pixel structure is visible in the illumination pattern, which is due to the pixel-like illumination of the illumination field by the LED pixel headlight. The pixel structure in the upper part of the illumination pattern differs from the pixel structure in the lower part. The pixel size in the lower part is approximately 0.1° in both the horizontal and vertical directions. In the upper part, the pixels have an elongated structure and a vertical orientation. The pixel size in the upper part is approximately 0.5° in the vertical direction and approximately 0.1° in the horizontal direction.This vertical elongation of the pixels is due to optical element 9, which widens the partial light rays of the first group vertically. Because of the elongated, vertically oriented pixels, the entire high beam range of the headlight can be covered with just a few pixel rows.

[0041] The headlight resolution, or rather the angular resolution of the headlight in the horizontal direction, is the same in both areas and is approximately 0.1°. This angular resolution enables high-resolution low beam functionality in the first projection area 20 and high-resolution HD functionality in the second projection area 30. Using headlight module 1, the high-resolution HD functionality and the glare-free high beam can thus be easily implemented in a single headlight module.

[0042] In some embodiments, the headlight module is designed to illuminate one or more additional projection areas or functional areas. In particular, the headlight optics can be designed as a multi-focus optic or comprise a multi-focus optic, especially with asymmetrical optical elements. With the aid of these asymmetrical optical elements, for example, lenses with asymmetrically curved lens surfaces, different projection areas, which can also have different geometries, can be illuminated. Thus, several functionalities, such as high beam, HD light, cornering light, and / or fog light, can be implemented in a single headlight module.

[0043] Although at least one exemplary embodiment has been shown in the preceding description, various changes and modifications can be made. The embodiments mentioned are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the preceding description provides the person skilled in the art with a plan for implementing at least one exemplary embodiment, whereby numerous changes can be made to the function and arrangement of elements described in an exemplary embodiment without departing from the scope of protection of the appended claims and their legal equivalents. Furthermore, according to the principles described herein, several modules or several products can also be combined to obtain additional functions. Reference symbol list

[0044] 1 Headlight module 2 Housing 3 First end 4 Second end 5 Light exit window 6 LED module 7 Headlight optics 8 Main beam direction 9 Optical element 10 Body 11 Mounting element 12 Primary optics 20 first projection area 30 second projection area 50 illumination area

Claims

1. Headlight module (1) of a vehicle headlight for generating a headlight for the pixel-like illumination of a high beam projection region (20) and a near light projection region (30), comprising: - an LED module (6), comprising an LED pixel array with a number of LED pixels for emitting in each case a LED light, wherein individual LED pixels of the LED module (6) separately and independently of one another can be driven, and - a headlight optical system (7) having an optical element (9) which is arranged within a housing (2) between the LED module (6) and a light exit window (5), wherein the light exit window (5) is designed as a collecting and / or scattering lens, wherein the housing (2) is designed essentially axially symmetrically about an axis of symmetry (8), wherein the axis of symmetry (8) corresponds to a main radiation direction of the headlight module (1), and wherein the optical element (9) is designed to shape the respective LED light into a respective partial light beam for illuminating in each case a partial region of the high-beam projection region (20) and of the high-beam projection region (30), wherein the optical element (9) is designed to illuminate the high-beam projection region (20) is illuminated by a first group of the partial light beams and the near-light projection region (30) is illuminated by a second group of the partial light beams, characterised in that the optical element (9) is designed as a free-form lens and serves to expand a projection region of partial light beams, wherein the free-form lens is arranged in the housing (2) above the axis of symmetry (8) and is preferably designed as a lens system (7), and the free-form lens is designed in such a way that the projection regions of the first group of partial light beams are expanded in a vertical direction, wherein the free-form lens is designed in such a way that the partial light beams of the first group have a horizontal opening angle of approximately 0.1° or lower and a vertical opening angle of approximately 0.2° or more, and that the partial light beams of the second group have an opening angle 0,1° or less in both the vertical and horizontal directions.

2. Headlight module according to the preceding claim, wherein the high-beam projection region (20) and the near-beam projection region (30) touch and / or partially overlap.

3. Headlight module according to one of the preceding claims, wherein the free-form lens is designed in such a way that the high-beam projection region (20) extends over a vertical angular range of -4° to +6°, in particular -2° to +3°.

4. Headlight module according to one of the preceding claims, wherein the free-form lens is designed in such a way that the near-light projection region (30) extends over a vertical angular range of -10° to 0°, in particular -8° to -1°.

5. Headlight module according to one of the preceding claims, wherein the free-form lens (9) is designed in such a way that it is detected essentially only by the first group of partial beams.

6. Headlight module according to one of the preceding claims, wherein the optical element (9) is designed as an additional element and is inserted into the housing (2).

7. Vehicle headlight for generating a headlight with a first projection region (20) and with a second projection region (30), wherein the vehicle headlight at least one headlight module (1) according to any one of the preceding claims.

8. Vehicle, wherein the vehicle has at least one vehicle headlight according to the preceding claim.