Hotspot Cutoff D-Optic for LED Headlamp Beam Control
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Solution Overview
Problem
Current LED headlamp designs are costly, complex, and inefficient, with insufficient intensity in the center of the beam pattern and 'banding effects' due to incomplete light distribution, and they fail to meet glare requirements for oncoming drivers.
Innovation Solution
The development of tall, thin optics with specific curved and sloped surfaces, and additional features like multi-cycle waves on the output surface, which allow for higher intensity and sharp gradients to produce desired beam patterns, including high beam and low beam hotspots, while minimizing glare.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a projector system is used to build high beam hotspot and imaged masks, then beam pattern intensity and sharp cutoff are improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the projector system from the headlamp design, replacing it with a simplified LED directly coupled to an optical element. This removes the complex mask imaging system while maintaining the desired beam pattern intensity through optimized optical surfaces.
Solution Approach 2:
The optical element is designed to perform multiple functions simultaneously: it creates the high beam hotspot, defines the low beam cutoff, and controls glare patterns all through a single integrated component rather than requiring separate projector systems for each function.
2Device complexity
If a simple wide beam optic is used, then device complexity is reduced, but illumination intensity in the center of the beam pattern becomes insufficient
Solution Approach 1:
The optical element features locally varied surface properties with different zones having distinct functions: the top surface creates the high beam hotspot, the bottom surface defines the low beam cutoff, and side walls control horizontal spread. This local differentiation achieves high intensity and sharp gradients without complex overall system design.
3Ease of manufacture
If light source does not illuminate entire input surface, then manufacturing is simplified, but banding effect appears in beam pattern
Solution Approach 1:
The patent introduces vertical dimension variations through the optical element's height and surface profiling to redistribute light uniformly across the output. The tall, thin geometry with varied surface heights creates overlapping light paths that eliminate banding effects while maintaining manufacturing simplicity.
4Object-affected harmful factors
If traditional optics are used to meet glare requirements, then glare control is improved, but beam pattern completeness deteriorates
Solution Approach 1:
The optical element employs asymmetric geometry with different surface configurations for top and bottom, and left and right sides. This asymmetry enables independent control of glare patterns in different directions while maintaining complete beam patterns, as the uneven surface profiles redirect light away from oncoming driver eyes without compromising overall illumination coverage.
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
These optics achieve improved photometric performance, higher intensity, and reduced 'banding effects' by efficiently distributing light, enabling the creation of complete beam patterns with enhanced on-road performance and compliance with glare regulations.
Implementation Method 1
A series of sloped, planar walls near the input port coupled with the thin crossection combine to create a smooth, wide horizontal light pattern having a sharp, controllable gradient in the vertical direction
Implementation Method 2
A series of sloped, planar walls near the input port coupled with the thin crossection combine to create a smooth, wide horizontal light pattern having a sharp, controllable gradient in the vertical direction
Implementation Method 3
The present invention is an optic used for producing a desired beam pattern according to claim 1. The optic has a body, a curved output surface, and specially shaped top, bottom, and side walls
Data Source
Figure 1~2
Figure 3A~3C
Figure 4
AI summary
The present invention is an optic (10) used for producing a desired beam pattern having a body portion (12) having a height and a thickness, and at least one sidewall profile, as well as an input port (301) for receiving light from a light source. The optic of the present invention also includes an output surface (304) 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 at least one leg portion, the at least one alignment feature for controlling the alignment of the optic in relation to the light source.