Vehicle Headlight Pixel Stitching for Seamless Far-Field Patterns

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current headlight assemblies require multiple optical projectors to achieve desired illumination patterns, increasing cost due to specialized tools and components, and struggle to provide both wide spread and high intensity without pixel overlap leading to blurring.

Innovation Solution

A headlight assembly with two or more projector units, each equipped with pixel light sources, controlled by a controller to produce non-overlapping far-field illumination patterns with seamless transitions, using digital micromirror devices or LED elements, allowing for high-definition lighting without pixel overlap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple optical projectors with differing prescriptions are used to achieve both wide spread and high intensity, then illumination pattern requirements are met, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveillumination pattern capabilityVSAvoidnumber of projector units

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The illumination pattern is segmented into multiple zones (central high-intensity zone and peripheral wide-spread zones), with each projector unit assigned to illuminate a specific zone. This allows each projector to be optimized for its designated function while collectively achieving the complete illumination pattern, resolving the contradiction between versatility and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple projector units with different optical prescriptions are integrated into a single headlight assembly, where each projector serves a specific function (central illumination or peripheral illumination). This multi-functional approach enables the system to meet diverse illumination requirements without requiring a single complex projector to handle all functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple projector units are used to provide both wide spread and high intensity, then illumination requirements are met, but manufacturing cost increases due to specialized tools and components

Engineering Contradiction:

Improveillumination pattern capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By segmenting the illumination task across multiple specialized projector units, each can be manufactured using standardized processes for their specific optical prescription. This modular segmentation allows for more efficient manufacturing compared to producing a single complex multi-functional projector, thereby reducing overall manufacturing cost while maintaining illumination versatility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses projector units with different optical parameters (prescriptions) to achieve varying illumination characteristics. By changing the optical parameters of individual projectors rather than creating a single complex projector, the system achieves cost-effective manufacturing through standardized production of specialized components.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If pixel light sources are used to define boundary edges with seamless transitions, then illumination pattern precision is improved, but control complexity increases

Engineering Contradiction:

Improveboundary edge definition accuracyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The boundary edges between illumination zones are defined by dedicated pixel light sources assigned to specific boundary segments. This segmentation of boundary definition tasks allows for precise control of each boundary independently, achieving high manufacturing precision while managing control complexity through modular boundary control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Pixel light sources are strategically positioned and controlled to provide local quality adjustments at boundary edges. Each pixel can be independently controlled to create seamless transitions only where needed at the boundaries, rather than requiring complex global control, thereby achieving precision with manageable control complexity.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12523350B2Digital stitching high-resolution lighting patterns for vehicle headlights

Publication Date: 2026.01.13 AUTOSYSTEMS BELLEVILLE INC

AI summary

A headlight assembly for a vehicle includes a first projector unit and a second projector unit. The first projector unit has a first light source and is configured to project light over a first far-field illumination pattern defining a first boundary edge. The second projector unit has a second light source and is configured to project light over a second far-field illumination pattern defining a second boundary edge. The first light source includes a first plurality of pixel light sources that is controllable to define the first boundary edge, and the second light source includes a second plurality of pixel light sources that is controllable to define the second boundary edge, with the first boundary edge abutting the second boundary edge, thereby producing a seamless transition between the first far-field illumination pattern and the second far-field illumination pattern.