LED Retrofit Lamps for Automotive Lighting Systems and Manufacturing Methods

Abstract

The light-emitting diode (LED) retrofit lamp includes a lamp body, an LED light source, an attachment ring, and at least one fastening element. The lamp body has at least one opening. The resilient element is coupled to the lamp body at a first end. The LED light source is coupled to the lamp body at a second end opposite the first end. The attachment ring includes a first wavy axial end face and a second axial end face opposite the first wavy axial end face. The first wavy axial end face includes a plurality of wave troughs and wave crests. The second axial end face abuts the resilient element. The at least one fastening element is disposed through at least one of the at least one opening in the lamp body and at least one of the wave troughs of the first wavy axial end face of the attachment ring.

Description

[Technical Field]

[0001] (Reference to Related Application) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 048,594, filed July 6, 2020, and European Patent Application No. 20189759.2, filed August 6, 2020, the contents of which are incorporated herein by reference. [Background technology]

[0002] Light-emitting diodes (LEDs) are rapidly gaining popularity due to their long life and low-energy performance. Advances in manufacturing have led to the emergence of chip-sized LED packages or modules in which at least one LED, often multiple LEDs, are packaged together in a matrix-like fashion, for example, including multiple rows of LEDs. Application areas for such LED modules include, but are not limited to, automotive front lighting, such as vehicle headlamps. Summary of the Invention

[0003] A light-emitting diode (LED) retrofit lamp includes a lamp body, an LED light source, an attachment ring, and at least one fastening element. The lamp body has at least one opening therein. The resilient element is coupled to the lamp body at a first end. The LED light source is coupled to the lamp body at a second end opposite the first end. The attachment ring includes a first wavy axial end face and a second axial end face opposite the first wavy axial end face. The first wavy axial end face includes a plurality of wave troughs and wave crests. The second axial end face abuts the resilient element. The at least one fastening element is disposed through at least one of the at least one opening in the lamp body and at least one of the wave troughs of the first wavy axial end face of the attachment ring.

[0004] A more detailed understanding may be had from the following description, given by way of example in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0005] [Figure 1] 1 is a perspective side view of an exemplary LED retrofit lamp.

[0006] [Figure 2] FIG. 2 is a side view of the exemplary LED retrofit lamp of FIG. 1.

[0007] [Figure 3] 3 is an enlarged partial side view of a portion of the LED retrofit lamp enclosed in FIG. 2.

[0008] [Figure 4] FIG. 1 is an enlarged partial side view of another exemplary LED retrofit lamp.

[0009] [Figure 5] 2A is a first enlarged partial perspective cross-sectional view of the LED retrofit lamp of FIG. 1 illustrating a first operating state, and FIG. 2B is a second enlarged partial perspective cross-sectional view of the LED retrofit lamp of FIG. 1 illustrating a second operating state.

[0010] [Figure 6] FIG. 1 is a flow diagram of a method for assembling an LED retrofit lamp.

[0011] [Figure 7] 1 is a diagram of an example of an exemplary vehicle headlamp system.

[0012] [Figure 8] FIG. 2 is a diagram of another exemplary vehicle headlamp system. DETAILED DESCRIPTION OF THE INVENTION

[0013] Examples of different optical illumination system and / or light emitting diode ("LED") implementations are described more fully below with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example can be combined with features found in one or more other examples to achieve additional implementations. Accordingly, it will be understood that the examples shown in the accompanying drawings are provided for illustrative purposes only and that they are not intended to limit the present disclosure in any way. Like numbers refer to like elements throughout.

[0014] Although the terms "first," "second," "third," etc. may be used herein to describe various elements, it will be understood that these elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be referred to as a second element, and a second element may be referred to as the first element, without departing from the scope of the present invention. As used herein, the term "and / or" may include any and all combinations of one or more of the associated listed items.

[0015] When an element, such as a layer, region, or substrate, is referred to as being "on" or extending "onto" another element, it will be understood that it may be directly on or extending directly onto the other element, or that intervening elements may be present. In contrast, when an element is referred to as being "directly on" or extending "directly onto" another element, there may be no intervening elements present. When an element is referred to as being "connected" or "coupled" to another element, it will also be understood that it may be directly connected or coupled to the other element and / or may be connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements between the element and the other element. It will be understood that these terms are intended to encompass different orientations of the elements in addition to any orientations depicted.

[0016] Relative terms such as "below," "above," "upper," "lower," "horizontal," or "vertical" may be used herein to describe the relationship of an element, layer, or region to another element, layer, or region as depicted. It will be understood that these terms are intended to encompass different orientations of the device in addition to the orientation depicted.

[0017] While LEDs are becoming increasingly popular, many conventional incandescent lamps or bulbs (e.g., halogen lamps) are still in use, for example, as vehicle headlamps. The angular emission of conventional incandescent lamps is close to 360 degrees, and conventional lighting fixtures are designed to efficiently use most of the generated light. With this in mind, it may be desirable to replace conventional lamps, such as halogen bulb lamps in automotive headlamps, with LED retrofit lamps without replacing the original lamp fixtures or sockets, and even the entire lamp housing and lamp, respectively. Consequently, LED retrofit lamps may use the same lamp mounts or fixtures as incandescent lamps, thereby facilitating cost-effectiveness, easy installation, and short setup times.

[0018] However, the light emission angle range of an LED retrofit lamp may be limited due to the directional light emission characteristics of the LED light source or LED package, respectively. Therefore, a proper rotational position of the LED retrofit lamp may be required to improve light beam performance or to comply with applicable regulations.

[0019] Thus, there may be a need for LED retrofit lamps with improved performance, where performance may be evaluated with respect to, among other things, quality of lighting performance, ease of installation, setup time, and ease and cost of manufacturing. The described embodiments provide LED retrofit lamps, such as for use in vehicle headlamps, that may offer high lighting performance, improved ease of installation and setup time, and improved ease and cost of manufacturing.

[0020] FIG. 1 is a perspective side view of an exemplary LED retrofit lamp 1. FIG. 2 is a side view of the exemplary LED retrofit lamp of FIG. 1. FIG. 3 is an enlarged partial side view of a portion of the LED retrofit lamp 1 that is enclosed in FIG. 2. The LED retrofit lamp 1 illustrated in FIGS. 1, 2, and 3 may function as a replacement lamp for a conventional incandescent lamp, such as a halogen bulb lamp, in a vehicle headlamp (shown in block diagram form in FIGS. 7 and 8). While the use of an LED retrofit lamp according to embodiments described herein may be as a replacement lamp for a vehicle headlamp, this is merely one example, and other application areas may be contemplated.

[0021] The exemplary LED retrofit lamp 1 shown in FIGS. 1 and 2 includes an LED light source 2, a lamp body 3, and an attachment ring 4. In the example shown in FIGS. 1 and 2, the LED light source 2 includes two separate LED light modules, each including a plurality of individual LEDs. However, the embodiments described herein are not limited to the specific number and / or arrangement of individual LEDs or LED packages / modules shown in FIGS. 1 and 2. The LED light source 2 (e.g., LEDs or LED packages) may be attached to the lamp body 3. The attachment ring 4 may be engageable with and rotatable relative to the lamp body 3. The attachment ring 4 may be configured to be attachable to a lamp holder (not shown). The attachment ring 4 of the exemplary LED retrofit lamp 1 may include, but is not limited to, a bayonet coupling 5 for attachment to a lamp holder. The bayonet joint 5 may allow for the installation of an LED retrofit lamp by a simple linear insertion movement followed by a rotational movement and vice versa.

[0022] The exemplary LED retrofit lamp 1 shown in Figures 1, 2 and 3 also includes at least one fixing element 6 releasably engageable with both the lamp body 3 and the attachment ring 4 so as to, in its engaged state, securely fix the attachment ring 4 in one of a plurality of predetermined angular positions relative to the lamp body 3. The rotational movability of the attachment ring 4 relative to the lamp body 3 is indicated by arrow 7 in Figure 1.

[0023] In the example of Figures 1, 2 and 3, two such fixing elements 6 are provided, only one of which is visible in Figures 1, 2 and 3. However, there may be only one fixing element 6, or more than two fixing elements (e.g. three, four, five or six fixing elements) may be provided to engage with the attachment ring 4 when fixed to the lamp body 3.

[0024] In the embodiment illustrated in FIGS. 1, 2, and 3, the fixing elements 6 are screws that may be threaded into respective threaded holes formed in the lamp body 3. In the illustrated example, for each screw 6, only one single respective threaded hole may be provided in the lamp body 3 of the LED retrofit lamp 1. If more than one threaded hole is provided in the lamp body 3, the threaded holes may be, for example (but not limited to), equally spaced and arranged circumferentially on the lamp body 3. It should also be understood that more threaded holes than the number of fixing elements 6 may be provided in the lamp body 3, thereby facilitating even finer angular adjustment of the attachment ring 4 relative to the lamp body 3, as will become more apparent further below. The use of screws as fixing elements may enable non-destructive and easy removal of the fixing elements and re-installation of the fixing elements in a quick and comfortable manner.

[0025] It can be observed from FIG. 1 that the angular position of the attachment ring 4 relative to the lamp body 3 may be fixed by the fixing element 6 through form-locking. In the example illustrated in FIGS. 1, 2 and 3, the attachment ring 4 of the LED retrofit lamp 1 has a wave-like axial end surface with a plurality of wave troughs 8 and wave crests 9. A fixing element 6, such as a screw or screws 6 in the illustrated example, may engage with one of the wave troughs 8 of the attachment ring 3 when engaged with the lamp body 3. This form-locked coupling between the fixing element 6 fixed to the lamp body 3 and the wave troughs 8 of the attachment ring 4 may ensure a strong and robust connection that can withstand the torque force required to operatively engage the bayonet coupling 5 (bayonet coupler) of the lamp holder with the bayonet catch (both the bayonet catch and the bayonet coupling are not shown). The total number of wave troughs 8 separated from one another by wave crests 9 as well as the specific distance between adjacent wave troughs 8 and wave crests 9 may determine the specific number and exact angles at which the attachment rings 4 may be positioned relative to the lamp body 3, respectively.

[0026] It should be noted that all wave troughs 8 provided on the axial end face of the attachment ring 4 may be equidistantly distributed so as to allow angular adjustment of the attachment ring 4 relative to the lamp body 3 at evenly distributed angular distances. However, it may also be envisaged to distribute the wave troughs 8 irregularly along the axial end face of the attachment ring, thereby, for example, allowing fine angular adjustment of a particular texture only within a predetermined angular range while excluding other angular ranges. In this way, for example, appropriate regulations may be precisely complied with and / or the lighting performance of the LED retrofit lamp may be optimized and / or assembly errors may be prevented.

[0027] Furthermore, in the example illustrated in FIGS. 1, 2, and 3, the attachment ring 4 is biased against the fixing element 6 by a resilient element 10 (illustrated, but not limited to, as an elastic O-ring in FIGS. 1, 2, and 3). The O-ring may facilitate easy installation, cost-effective manufacturing of the LED retrofit lamp, and sealing of the lamp portion inserted into the headlamp module from the environment. Other resilient elements may be envisioned, such as springs made of metal or plastic materials, coil springs, disc springs, spring washers, resilient clips and / or clamps, rubber elements, and the like. This may improve the torque-proof coupling of the attachment ring and lamp body with the fixing element. Furthermore, potential axial play between the attachment ring and lamp body may be effectively eliminated, thereby preventing rattle and harmful wear between the moving parts.

[0028] The resilient elements 10 may press the attachment ring 4 against the fixing element 6 when secured to the lamp body 3, thus further improving the form-locking connection between the respective wave troughs 8 and the fixing element 6. In addition, potential (axial) play between the lamp body 3 and the attachment ring 4 may be eliminated. In this way, the relative angular position of the attachment ring with respect to the lamp body, and consequently also the relative angular position of the LED light source with respect to the lamp holder when attached to the lamp holder, may be firmly maintained during installation of the retrofit lamp, especially if installation requires applying a rotational movement of the LED retrofit lamp to achieve proper fixation of the LED retrofit lamp in the lamp holder. The form-locking engagement of the fixing means may be configured to withstand such torsional forces during the installation process.

[0029] 1, 2, and 3, the O-ring 10 may be fixedly disposed on the lamp body 3 and may abut against a second axial end face of the attachment ring 4 (the axial end face opposite to the axial end face of the attachment ring 3 on which the wave troughs 8 and wave crests 9 are formed). The resilient element 10 may be sandwiched between the heat sink 20 of the LED retrofit lamp 1 and the attachment ring 4, but is not limited to such a configuration.

[0030] 4 is an enlarged partial side view of another exemplary LED retrofit lamp. The LED retrofit lamp illustrated in FIG. 4 basically corresponds to the configuration of the LED retrofit lamp 1 shown in FIG. 1, except for the attachment ring 11 and the fixing element 12.

[0031] In the example illustrated in FIG. 4 , the fastening element 12 is a pin, which may be securely insertable into the lamp body 3. Furthermore, the attachment ring 11 of the LED retrofit lamp illustrated in FIG. 4 may include a plurality of circumferentially distributed through-holes 13. When engaged with the lamp body 3, the pin 12 may pass through one of the through-holes 13 of the attachment ring 11, forming a form-lock connection as described herein. Similar to the embodiments illustrated in FIGS. 1 , 2 , and 3 , one, two, or more pins 12 may be provided to securely secure the attachment ring 11 in a predetermined angular position relative to the lamp body 3. If such an embodiment is used, rather than threading the fastening element, it may be clamped and / or locked to the lamp body, thereby enabling non-destructive removal and reinstallation of the fastening element in a simple manner in a minimal amount of time. In embodiments, the through-holes may be manufactured by cost-effective machining, drilling, casting, or the like, while promoting a robust form-lock connection.

[0032] The circumferential distribution of the through holes 13 in the attachment ring 11 may be as described above relative to the circumferential distribution of the wave valleys 8 in the attachment ring 4 of the LED retrofit lamp 1 of FIGS. 1, 2, and 3. Furthermore, it should be noted that the combination of the through holes 13 in the attachment ring 11 and the pins 12 as fastening elements shown in FIG. 4 is not a required combination. Rather, according to yet another embodiment (not shown), the attachment ring may include the wave valleys 8 and wave crests 9 shown in the embodiment of the LED retrofit lamp 1 of FIGS. 1-3, while having the pins 12 as fastening elements instead of the screws 6 of the LED retrofit lamp 1 shown in FIGS. 1, 2, and 3. In this case, it should be understood that the pins 12 may engage with one of the wave valleys 8 to secure the attachment ring in a predetermined desired angular position relative to the lamp body.

[0033] In yet another embodiment (also not shown), the attachment ring may include the through holes 13 of the LED retrofit lamp embodiment shown in Figure 4, but have as the fastening elements the screws 6 of the LED retrofit lamp 1 embodiment instead of the pins 12 shown in Figure 4. In this case, the screws may pass through one of a plurality of through holes 13 provided in the attachment ring to properly secure the attachment ring at one of a plurality of predetermined angular positions relative to the lamp body.

[0034] 5A is a first enlarged partial perspective cross-sectional view of the LED retrofit lamp 1 of FIG. 1 showing a first operating state, and FIG. 5B is a second enlarged partial perspective cross-sectional view of the LED retrofit lamp 1 of FIG. 1 showing a second operating state.

[0035] In a first operating state (A), the fixing elements 6 (e.g., screws 6 in the illustrated embodiment) may be fixed in respective threaded holes 14 in the lamp body 3 while engaging with respective wave troughs 8 of the attachment ring 4. In this state, the attachment ring 4 may be rotationally fixed relative to the lamp body 3 at a selected angular position.

[0036] In a second operating state (B), the screws 6 may be removed from their respective threaded holes 14, thus facilitating free rotational movement of the attachment ring 4 relative to the lamp body 3. In this way, a new angular position of the attachment ring 4 relative to the lamp body 3 may be selected corresponding to the wave troughs 8 available at the axial end faces of the attachment ring 4.

[0037] In embodiments, the attachment ring may be formed from a material including one of polyphenylene sulfide (PPS), polyvinyl toluene (PVT), polyamide 6,6 (PA66), polyamide 4,6 (PA46), liquid crystal polymer (LCP), polyether ether ketone (PEEK), polyphthalamide (PPA), resin grades, or any combination thereof. The attachment ring may be manufactured using, for example, injection molding. Alternatively or additionally, the attachment ring may be manufactured from a material including at least one of glass fiber and carbon fiber, which provides additional rigidity and robustness to the attachment ring. The use of such materials and manufacturing processes may result in improved ease of manufacturing and reduced costs, such as by using injection molding processes to manufacture O-rings.

[0038] FIG. 6 is a flow diagram of a method for assembling a light-emitting diode (LED) retrofit lamp. In the example shown in FIG. 6, the method includes providing a lamp body (602). In an embodiment, the lamp body may include, for example, at least one opening, a resilient element coupled to the lamp body at a first end, and an LED light source coupled to the lamp body at a second end opposite the first end. The method may also include providing an attachment ring (604). In an embodiment, the attachment ring may include, for example, a first wavy axial end face and a second axial end face opposite the first wavy axial end face. The first wavy axial end face may include a plurality of wave troughs and a plurality of wave crests, and the second axial end face may abut the resilient element.

[0039] The attachment ring may be rotated about the lamp body (606). In embodiments, the attachment ring may be rotated about the lamp body until the attachment ring is in a desired angular position relative to the lamp body. The attachment ring may be secured to the lamp body (608). The attachment ring may be secured to the lamp body at least in part by inserting a fastening element through an opening in the fastening element and engaging one of the plurality of wave troughs.

[0040] In embodiments, the wavy end faces may be manufactured, for example, by machining, casting, or the like, thereby improving ease and cost of manufacture while promoting a robust form-lock connection.

[0041] As mentioned above, embodiments of the LED retrofit lamp described herein may be used, for example, in automotive lighting systems. In such systems, for example, the LED retrofit lamp may be attached to a lamp holder, such as a lamp mount or fixture for a vehicle headlamp, by an attachment ring. During times when the fixing element is removed from the lamp body, the attachment ring may be rotated relative to the lamp body. With the fixing element attached to the lamp body, the fixing element may engage with the attachment ring such that the attachment ring may be securely fixed in one of several predetermined angular positions relative to the lamp body.

[0042] The attachment ring may be attachable to a lamp holder, for example, and may provide a mounting element for mounting to the lamp holder. Consequently, when the LED retrofit lamp is mounted in the lamp holder, it may ensure a predetermined angular position of the LED light source relative to the lamp holder. Thus, the proper light emission direction of the LED light source of the LED retrofit lamp for optimal lighting performance can always be ensured in any lamp holder. Thus, the LED retrofit lamp according to the embodiments described herein may be easily adapted to a specific lamp holder so as to always provide maximum / optimal lighting performance and / or compliance with respective regulations when mounted in a given lamp holder.

[0043] Furthermore, installation of the attachment ring to the lamp body of the LED retrofit lamp may be accomplished in the shortest possible time by simply removing the fixing means, rotating the attachment ring to its desired angular position, and finally re-engaging the fixing means with both the lamp body and the attachment ring, thus further improving ease of use.

[0044] 7 is a diagram of an example vehicle headlamp system 700 that may incorporate one or more of the embodiments and examples described herein. The example vehicle headlamp system 700 shown in FIG. 7 may include a power line 702, a data bus 704, an input filter and protection module 706, a bus transceiver 708, a sensor module 710, an LED direct current to direct current (DC / DC) module 712, a logic low-dropout (LDO) module 714, a microcontroller 716, and active headlamps 718.

[0045] The power line 702 may have an input for receiving power from the vehicle, and the data bus 704 may have inputs / outputs for exchanging data between the vehicle and the vehicle headlamp system 700. For example, the vehicle headlamp system 700 may receive commands from elsewhere in the vehicle, such as a command to turn on turn signaling or a command to turn on the headlamps, and may send feedback to elsewhere in the vehicle as needed. A sensor module 710 may be communicatively coupled to the data bus 704 and may provide additional data to the vehicle headlamp system 700 or elsewhere in the vehicle, related to, for example, environmental conditions (e.g., time of day, rain, fog, or ambient light levels), vehicle status (e.g., parked, moving, speed, or direction of travel), and the presence / location of other objects (e.g., vehicles or pedestrians). A headlamp controller, separate from any vehicle controller communicatively coupled to the vehicle data bus, may also be included in the vehicle headlamp system 700. In FIG. 7 , the headlamp controller may be a microcontroller, such as microcontroller (μc) 716. The microcontroller 716 may be communicatively coupled to the data bus 704 .

[0046] An input filter and protection module 706 may be electrically coupled to the power line 702 and may support various filters, for example, to reduce conducted emissions and provide power immunity. Additionally, the input filter and protection module 106 may provide electrostatic discharge (ESD) protection, load dump protection, alternator field decay protection, and / or reverse polarity protection.

[0047] An LED DC / DC module 712 may be coupled between the input filter and protection module 706 and the active headlamp 718 to receive the filtered power and provide drive power to power the LEDs in an LED array in the active headlamp 718. The LED DC / DC module 712 may have an input voltage between 7 volts and 18 volts, with a nominal voltage of approximately 13.2 volts, and an output voltage that may be slightly (e.g., 0.3 volts) higher than the maximum voltage for the LED array (e.g., as determined by coefficients or local calibration and operating condition adjustments due to load, temperature, or other factors).

[0048] A logic LDO module 714 may be coupled to the input filter and protection module 706 to receive filtered power. The logic LDO module 714 may also be coupled to the microcontroller 716 and the active headlamp 718 to provide power to the microcontroller 716 and / or electronics within the active headlamp 718, such as CMOS logic.

[0049] The bus transceiver 708 may have, for example, a universal asynchronous receiver transmitter (UART) or a serial peripheral interface (SPI) interface and may be coupled to a microcontroller 716. The microcontroller 716 may convert vehicle input based on or including data from the sensor module 710. The converted vehicle input may include a video signal that can be transferred to an image buffer in the active headlamp 718. Additionally, the microcontroller 716 may load a default image frame and test for open / short pixels during startup. In embodiments, the SPI interface may load the image buffer into CMOS. The image frame may be a full frame, a differential frame, or a partial frame. Other configurations of the microcontroller 716 may include a control interface monitoring CMOS status, including die temperature as well as logic LDO outputs. In embodiments, the LED DC / DC output may be dynamically controlled to minimize headroom. In addition to providing image frame data, other headlamp functions may also be controlled, such as complementary use with side marker or turn signal lights, and / or activation of daytime running lights.

[0050] Figure 8 is a diagram of another example vehicle headlamp system 800. The example vehicle headlamp system 800 shown in Figure 8 includes an application platform 802, two LED lighting systems 806 and 808, and secondary optics 810 and 812.

[0051] LED lighting system 808 may emit a light beam 814 (shown between arrows 814a and 814b in FIG. 8 ). LED lighting system 806 may emit a light beam 816 (shown between arrows 816a and 816b in FIG. 8 ). In the embodiment shown in FIG. 8 , secondary optics 810 is adjacent to LED lighting system 808, and light emitted from LED lighting system 808 passes through secondary optics 810. Similarly, secondary optics 812 is adjacent to LED lighting system 806, and light emitted from LED lighting system 806 passes through secondary optics 812. In an alternative embodiment, secondary optics 810 / 812 are not provided in the vehicle headlamp system.

[0052] If secondary optics 710 / 812 are included, the secondary optics 810 / 812 may be or may include one or more light guides. The one or more light guides may be edge-lit and may have an internal opening that defines the interior edge of the light guide. The LED illumination systems 808 and 806 may be inserted into the internal opening of the one or more light guides to inject light into the interior edge (internal opening light guides) or exterior edge (edge-lit light guides) of the one or more light guides. In embodiments, the one or more light guides may shape the light emitted by the LED illumination systems 808 and 806 in a desired manner, such as, for example, a gradient, a chamfered distribution, a narrow distribution, a wide distribution, or an angular distribution.

[0053] Application platform 802 may provide power and / or data to LED lighting systems 806 and / or 808 via lines 804, which may include one or more of or portions of power lines 702 and data bus 704 of FIG. 7. One or more sensors (which may be sensors within vehicle headlamp system 800 or other additional sensors) may be internal or external to the housing of application platform 802. Alternatively or additionally, as shown in example vehicle headlamp system 700 of FIG. 7, each LED lighting system 808 and 806 may include its own sensor module, connectivity and control module, power module, and / or LED array.

[0054] In an embodiment, vehicle headlamp system 800 may represent an automobile with a steerable light beam that may selectively activate LEDs to provide steerable light. For example, an array of LEDs or emitters may be used to define or project a shape or pattern, or to illuminate only selected sections of a road. In an exemplary embodiment, the infrared camera or detector pixels in LED lighting systems 806 and 808 may be sensors (e.g., similar to the sensors in sensor module 710 of FIG. 7 ) that identify portions of a scene (e.g., a road or crosswalk) requiring illumination.

[0055] Having described the embodiments in detail, those skilled in the art will appreciate, given the present description, that modifications may be made to the embodiments described herein without departing from the spirit of the inventive concept. Accordingly, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.

Claims

1. A light emitting diode (LED) retrofit lamp, comprising: a lamp body having a plurality of screw holes formed therein; a resilient element coupled to the lamp body at a first end; an LED light source coupled to the lamp body at a second end opposite the first end; an attachment ring including a first wavy axial end surface and a second axial end surface opposite the first wavy axial end surface, the first wavy axial end surface including a plurality of wave troughs and wave crests, and the second axial end surface abutting the resilient element; a plurality of screws, each screw being disposed through at least one of the plurality of screw holes formed in the lamp body and at least one of the wave troughs of the first wave-shaped axial end surface of the attachment ring; LED retrofit lamp.

2. 2. The LED retrofit lamp of claim 1, wherein each screw hole of the plurality of screw holes is removably engageable with both the lamp body and the attachment ring via the plurality of screw holes in the lamp body and the plurality of wave valleys of the first wavy axial end face of the attachment ring so as to securely fix the attachment ring at one of a plurality of predetermined angular positions relative to the lamp body in an engaged state.

3. 3. The LED retrofit lamp of claim 2, wherein the angular position of the attachment ring relative to the lamp body is fixed by the plurality of screws through form locks.

4. 2. The LED retrofit lamp of claim 1, wherein the plurality of screws also engage the wave valleys of the attachment ring when engaged with the lamp body.

5. ［７］ 2. The LED retrofit lamp of claim 1, wherein the attachment ring is biased against the plurality of screws by the resilient element when the attachment ring is engaged with the lamp body.

6. The LED retrofit lamp of claim 1 , wherein the resilient element is an O-ring.

7. 10. The LED retrofit lamp of claim 1, wherein the attachment ring includes a bayonet coupling for attachment to a lamp holder.

8. 10. The LED retrofit lamp of claim 1, wherein the attachment ring is formed from a material including one or more of polyphenylene sulfide (PPS), polyvinyl toluene (PVT), polyamide 6,6 (PA66), polyamide 4,6 (PA46), liquid crystal polymer (LCP), polyetheretherketone (PEEK), polyphthalamide (PPA), or resin grades.

9. 10. The LED retrofit lamp of claim 1, wherein the attachment ring is formed from a material including at least one of fiberglass and carbon fiber.

10. 1. A method of assembling a light emitting diode (LED) retrofit lamp, comprising:

1. A lamp body comprising: The lamp body is Multiple screw holes and a resilient element coupled to the lamp body at a first end; an LED light source coupled to the lamp body at a second end opposite the first end; providing a lamp body; providing an attachment ring, The attachment ring comprises: a first wavy axial end surface; a second axial end surface opposite the first wavy axial end surface; the first wavy axial end surface includes a plurality of wave troughs and wave crests, and the second axial end surface abuts the resilient element; providing an attachment ring; rotating the attachment ring around the lamp body until the attachment ring is in a desired angular position relative to the lamp body; and at least partially securing the attachment ring to the lamp body by inserting a respective thread of a plurality of screws through a respective threaded hole of the plurality of threaded holes in the lamp body to engage a respective wave trough of the plurality of wave troughs. method.

11. a vehicle headlamp including a lamp holder; LED retrofit lamps, 1. An automotive lighting system, comprising: The LED retrofit lamp is a lamp body having a plurality of screw holes formed therein; a resilient element coupled to the lamp body at a first end; an LED light source coupled to the lamp body at a second end opposite the first end; an attachment ring including a first wavy axial end surface and a second axial end surface opposite the first wavy axial end surface, the first wavy axial end surface including a plurality of wave troughs and wave crests, and the second axial end surface abutting the resilient element; a plurality of screws, each screw being disposed through at least one of the plurality of screw holes formed in the lamp body and at least one of the wave troughs of the first wave-shaped axial end surface of the attachment ring; The LED retrofit lamp is attached to the lamp holder of the vehicle headlamp via at least the attachment ring; Automotive lighting systems.

12. 12. The automotive lighting system of claim 11, wherein each thread of the plurality of screws is removably engageable with both the lamp body and the attachment ring via the plurality of threaded holes formed in the lamp body and the plurality of wave valleys of the first wavy axial end face of the attachment ring so as to securely fix the attachment ring at one of a plurality of predetermined angular positions relative to the lamp body in an engaged state.

13. 13. The automotive lighting system of claim 12, wherein the angular position of the attachment ring relative to the lamp body is fixed by the plurality of screws through form locks.

14. 12. The automotive lighting system of claim 11, wherein the plurality of threads also engage the plurality of wave troughs of the attachment ring when engaged with the lamp body.

15. 12. The automotive lighting system of claim 11, wherein the attachment ring is biased against the plurality of screws by the resilient element when the attachment ring is engaged with the lamp body.

Images