Vehicle Headlamp Light Array with Gradient Spacing
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Solution Overview
Problem
Existing vehicle headlamps with adaptive driving beams (ADB) face challenges in achieving high optical resolution for long-distance visibility while minimizing glare, particularly around the middle of the light-distribution pattern.
Innovation Solution
A lamp unit configuration featuring a light-emitting element array with individually controllable irradiation regions, a projection lens, and a reflector, where the interval between light-emitting elements increases with distance from the optical axis, and a shading plate is used to enhance optical resolution and prevent distortion, allowing for improved light utilization and glare reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the interval between light-emitting elements is uniform across the array, then the structure is simple and easy to manufacture, but the optical resolution of the high-beam light-distribution pattern around the center is insufficient
Solution Approach 1:
The patent applies local quality by varying the interval between light-emitting elements based on their position in the array. Specifically, the interval is smaller for elements near the optical axis and larger for elements farther from the optical axis. This non-uniform spacing optimizes the optical resolution of the high-beam light-distribution pattern around the center while maintaining manufacturing feasibility through a systematic gradient arrangement.
2Manufacturing precision
If more light-emitting elements are used to improve resolution, then the optical resolution improves, but the device complexity and cost increase
Solution Approach 1:
The patent changes the spatial parameter (interval) between light-emitting elements as a function of their position in the array. By implementing a gradient interval where spacing decreases toward the optical axis, the system achieves superior optical resolution in the critical central region without proportionally increasing the total number of elements, thus optimizing the balance between resolution and device complexity.
3Use of energy by moving object
If the substrate is inclined to improve light beam utilization, then the light utilization factor improves, but the alignment with the projection lens optical axis becomes more complex
Solution Approach 1:
The patent introduces asymmetry by inclining the substrate at a specific angle (5-15 degrees) relative to the projection lens optical axis. This asymmetric positioning optimizes the light beam utilization factor by directing more light toward the effective surface of the projection lens. The specific angle range balances improved light utilization with manageable alignment complexity in the headlamp assembly.
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 configuration significantly increases the resolution of the high-beam light-distribution pattern around the center, providing both broad-range diffused light and far-side visibility with a relatively small number of light-emitting elements, while minimizing glare and chromatic aberration effects.
Implementation Method 1
a projection lens disposed in front of the light-emitting element array
Implementation Method 2
a reflector disposed below the light-emitting element array
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A lamp unit 14 includes a light-emitting element array 40 composed by a plurality of light-emitting elements, having respective individual irradiation regions constituting a high-beam light-distribution pattern and configured to be capable of being turned on individually, mounted in array on a substrate, a projection lens 34 disposed in front of the light-emitting element array 40, and a reflector 38 disposed below the light-emitting element array 40. Inter-light-emitting-element interval within the light-emitting element array widens the more separated the elements are from the projection lens' optical axis.