Headlamp Module Edge-Type LED Lighting Distribution
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Solution Overview
Problem
Existing headlamp modules using LED light sources suffer from limited lighting area and high assembly complexity, resulting in dark or unlit areas around the module, and increased manufacturing costs due to their intricate structure.
Innovation Solution
A headlamp module design featuring a connecting base, substrate, and edge-type LED units mounted on opposite surfaces of the substrate, which provides even lighting and a 360-degree lighting scope by using a wavelength converting layer and light reflecting layer to distribute light effectively, simplifying the structure and reducing assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED assembly is used as light source, then energy saving and long lasting performance is improved, but lighting area coverage deteriorates due to strong directionality of emitted light
Solution Approach 1:
The headlamp module divides the lighting function into multiple edge-type LED units positioned at different locations (front, rear, left, right edges) of the lamp housing. Each LED unit emits light in a specific direction, and collectively they provide omnidirectional illumination covering the entire lighting area, resolving the directional limitation of single LED assemblies.
Solution Approach 2:
The patent transitions from traditional centralized LED assembly to edge-type LED units distributed along the perimeter of the lamp housing. This spatial redistribution in multiple dimensions enables light emission from all edges simultaneously, achieving 360-degree coverage and eliminating dark areas while maintaining LED energy efficiency.
2Adaptability or versatility
If reflector with multiple curvatures is used, then light distribution to different directions is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
Instead of using a single complex reflector with multiple curvatures, the patent segments the lighting system into multiple simple edge-type LED units positioned at different edges. Each unit provides directional illumination for its specific region, and together they achieve comprehensive light distribution without requiring complex reflective surfaces.
Solution Approach 2:
The patent extracts and removes the reflector component from the traditional headlamp structure. By positioning LED units directly at the edges of the lamp housing, the system eliminates the need for reflectors entirely, simplifying the structure while maintaining effective light distribution across all directions.
3Illumination intensity
If traditional headlamp structure with LED assembly and reflector is used, then lighting function is achieved, but manufacturing cost increases due to complicated structure
Solution Approach 1:
The patent removes the reflector component from the traditional headlamp assembly, eliminating the need for complex shaping, polishing, and coating processes associated with reflectors. This extraction of unnecessary components directly reduces manufacturing steps and costs while maintaining lighting performance through edge-type LED units.
Solution Approach 2:
The patent integrates the LED light source directly into the lamp housing structure at the edges, merging previously separate components (LED assembly, reflector, housing) into a unified design. This integration reduces the number of parts, simplifies assembly procedures, and lowers overall manufacturing cost while achieving the required lighting function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances the lighting angle and brightness around the headlamp module, reducing unlit areas and lowering manufacturing complexity and costs while maintaining a simple structure.
Implementation Method 1
The wavelength converting layer 42 covers the light emitting surface 411 and the first sidewalls 412
Implementation Method 2
The light reflecting layer 43 is located on the top surface 420 of the wavelength converting layer 42
Data Source
AI summary
A headlamp module comprises a connecting base, a substrate, and at least two edge-type light emitting diode (LED) units. The at least two edge-type LED units are mounted to opposite surfaces of the substrate facing away from each other. Each edge-type LED unit comprises an LED chip, a wavelength converting layer, and a light reflecting layer. The LED chip comprises a bottom surface, a light emitting surface facing away from the bottom surface, and first sidewalls. The wavelength converting layer covers the light emitting surface and the first sidewalls. The wavelength converting layer converts emitted light to a desired range of wavelengths. The light reflecting layer reflects the converted light toward the second sidewalls, thus expanding the angle and brightness of light around the headlamp module and avoiding an unlit or dark area immediately around the headlamp module.