Composite LED Module Layout for Uniform Vehicle Headlight Beams
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Solution Overview
Problem
Current LED technologies for high luminosity applications, such as vehicle headlighting, face challenges with insufficient luminous power from individual LEDs, leading to non-uniform illumination due to large separation distances and increased system complexity, especially when using primary optics, and thermal management becomes difficult with densely packed LEDs.
Innovation Solution
A novel LED module arrangement with a composite two-dimensional array on a substrate, where LEDs are oriented in alternating rows, allowing electrical connections on a single circuit level, enabling the use of ceramic substrates with a single metallization layer for thermal management, and incorporating switches for single addressability and fine-grained beam control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are densely packed to increase luminous power, then illumination intensity is improved, but thermal management becomes difficult
Solution Approach 1:
The LED array is divided into multiple independent strings that can be controlled separately. Each string contains LEDs connected in series, allowing selective activation of specific strings to distribute thermal load and manage heat generation in densely packed configurations.
Solution Approach 2:
The patent implements dynamic control of LED strings through individual addressing capabilities. Different strings can be turned on or off based on operational requirements, enabling adaptive thermal management by activating fewer strings when heat dissipation is critical while maintaining high illumination intensity when needed.
2Ease of operation
If primary optics are used for beam shaping, then beam control is improved, but system complexity increases
Solution Approach 1:
The patent replaces complex mechanical primary optics with electronic control of LED string configurations. By selectively activating different strings of LEDs with specific orientations, the system achieves beam shaping and control through electronic switching rather than complex optical mechanical components.
3Illumination intensity
If LEDs are arranged in alternating rows with different orientations, then uniform illumination is achieved, but electrical connection complexity increases
Solution Approach 1:
The patent merges LEDs of different orientations into alternating rows within a unified array structure. By organizing first LEDs (first orientation) and second LEDs (second orientation) in alternating rows on the same substrate, the design achieves uniform illumination while integrating electrical connections through a common substrate infrastructure, reducing overall connection complexity.
4Ease of operation
If individual LED addressing is implemented for fine-grained control, then beam control precision is improved, but device complexity increases
Solution Approach 1:
The LED array is segmented into multiple independently controllable strings, where each string can be individually addressed and controlled. This segmentation enables fine-grained beam control by activating specific strings with particular orientations, achieving precise beam shaping without requiring individual control of every single LED, thus managing complexity effectively.
Data Source
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AI summary
A composite array has two two-dimensional arrays on a substrate each having two rows of LEDs. The LEDs in each array have the same orientation as all other LEDs in that array. First electrical traces sequentially couple LEDs in the first string and the second string by beginning at opposite corners of the composite array and alternating between rows of each of the first and second arrays. A second electrical trace couples ends of the first and second strings across rows of the composite array. Third electrical traces route outside the composite array and are coupled, respectively, to a beginning of the first string for the row of the composite array containing the beginning of the first string, a beginning of the second string for the other row, the end of the first LED string for the other row, and electrodes of LEDs in the other row.