Hotspot Cutoff D-Optic for LED Headlamp Beam Control
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Solution Overview
Problem
Current LED headlamp designs face inefficiencies in producing high beam and low beam patterns due to the need for complex projector systems, insufficient intensity in the center of the beam pattern, and issues with glare reduction, particularly the 'banding effect' caused by uneven light distribution.
Innovation Solution
The development of a tall, thin optic with specific profiles and features such as curved surfaces, sloped walls, and multi-cycle waves to create high-intensity, sharp gradient beam patterns, capable of producing both high beam and low beam patterns with reduced glare and improved optical efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a projector system is used to build the high beam hotspot and imaged masks, then the beam pattern can be produced, but the system becomes costly, complex and inefficient
Solution Approach 1:
The patent combines the functions of multiple optical elements (projector system, imaged masks, and beam shaping components) into a single integrated optic. This single optic produces the complete beam pattern including high beam hotspot, low beam pattern, and cutoff characteristics that previously required separate components, thereby reducing system complexity and manufacturing cost while maintaining performance
Solution Approach 2:
The single optic is designed to perform multiple functions simultaneously: it creates the high beam hotspot, generates the low beam pattern with sharp cutoff, and provides glare reduction. This multi-functional design eliminates the need for separate projector systems and mask images, addressing the complexity issue while maintaining complete beam pattern production capability
2Loss of energy
If a wide beam pattern with tall thin optical elements is used, then efficiency is improved, but the intensity in the center of the pattern becomes insufficient
Solution Approach 1:
The optic employs different refractive index regions and optical densities at different locations within the single optic structure. The center portion is designed to concentrate and intensify light for the high beam hotspot, while the peripheral portions manage beam spread and cutoff. This local variation in optical properties allows simultaneous achievement of high center intensity and efficient beam distribution
Solution Approach 2:
The patent utilizes variations in optical parameters (refractive index, optical density, curvature) within the single optic to control light propagation. By changing these parameters spatially, the optic achieves both high efficiency beam spread and sufficient center intensity, resolving the contradiction between wide beam coverage and central illumination strength
3Illumination intensity
If a light source is used to provide light for an input surface, then illumination is provided, but the light does not provide light for the entire area of the input surface resulting in banding effect
Solution Approach 1:
The optic incorporates curved surfaces and spherical geometries that distribute light more uniformly across the output surface. The curved interfaces refract and redirect light rays to eliminate dark areas and banding effects, ensuring even illumination across the entire beam pattern while maintaining high intensity in critical regions
4Illumination intensity
If headlamps are directed towards driver's eyes to provide illumination, then visibility is improved, but glare is produced at oncoming driver's eye location
Solution Approach 1:
The single optic is designed with distinct functional zones that separate high beam and low beam patterns, as well as glare reduction functions. The optic creates sharp horizontal and vertical cutoffs that segment the light distribution, allowing high intensity illumination in appropriate directions while completely blocking light from reaching oncoming driver eye locations, thus eliminating glare without sacrificing visibility
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 solution effectively enhances beam pattern intensity and sharpness, reduces the 'banding effect,' and minimizes glare, achieving improved photometric performance and on-road illumination with a single LED, while accommodating glare reduction requirements.
Implementation Method 1
an optic used for producing a desired beam pattern with a body portion having a height and a thickness, and at least one sidewall profile, as well as an input port for receiving light from a light source
Implementation Method 2
curved output surface, and specially shaped top, bottom, and side walls
Data Source
AI summary
The present invention is an optic used for producing a desired beam pattern having a body portion having a height and a thickness, and at least one sidewall profile, as well as an input port for receiving light from a light source. The optic of the present invention also includes an output surface formed as part of the body portion on the opposite side of the body portion in relation to the input port, at least one leg portion formed as part of the body portion, and at least one alignment feature formed as part of the leg portion, the alignment feature for controlling the alignment of the optic in relation to the light source.