Integral Lighting Assembly for Automotive Headlamps
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Solution Overview
Problem
Conventional automotive headlamp lighting assemblies using separate light sources for high and low beams result in a 'gap' between the beams, leading to inadequate illumination of critical areas like the verge or curb region, compromising safety due to the physical separation and shared optics, which also increases the size of the arrangement.
Innovation Solution
An integral lighting assembly with collimators arranged to direct the first and second beams at separate regions of an optical arrangement, allowing them to overlap on a projection plane, eliminating the need for separate units and enabling separate manipulation of the beams to achieve optimal illumination without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If separate light sources are used for high beam and low beam, then beam functions can be generated, but a gap appears between the beams causing inadequate illumination
Solution Approach 1:
The patent divides the single optical arrangement into two distinct functional regions: an upper region for high beam and a lower region for low beam. Each light source is assigned to a specific region, allowing independent beam manipulation while maintaining overall system integration. This segmentation enables separate control of beam characteristics without physical interference between the beams.
Solution Approach 2:
The patent utilizes vertical spatial separation by positioning light sources at different heights (upper and lower positions) relative to the optical axis. This dimensional arrangement allows both beams to travel through the same optical arrangement without overlapping paths, eliminating the gap problem while maintaining compact horizontal footprint.
2Device complexity
If a shared optical element is used for both beams, then device size is reduced, but the optical element must be larger compromising compactness
Solution Approach 1:
The patent applies different optical properties to different regions of the shared optical element. The upper region of the optical arrangement is optimized for high beam characteristics while the lower region is optimized for low beam characteristics. This local differentiation allows a single optical element to perform multiple functions without requiring excessive size, as each region is tailored to its specific beam requirements.
3Reliability
If optical distortion is applied to close the gap between beams, then illumination continuity is improved, but the cut-off line quality deteriorates
Solution Approach 1:
By segmenting the optical arrangement into distinct upper and lower regions, the patent eliminates the need for optical distortion to close gaps between beams. Each region independently directs its beam without requiring warping or distortion of the optical element, thereby maintaining precise cut-off line quality while achieving continuous 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
This solution ensures optimal illumination of the region in front of the vehicle without dark gaps, maintaining compliance with regulatory beam patterns while achieving a compact and cost-effective LED headlamp solution.
Implementation Method 1
a first collimator for directing the first beam at the optical arrangement, and a second collimator for directing the second beam at the optical arrangement, wherein the collimators are arranged such that a collimator on one side of an optical axis of the lighting assembly directs its beam of light essentially at a region of the optical arrangement on the other side of the optical axis
Implementation Method 2
the optical arrangement is realized to manipulate the first and second light beams to give a low exit beam and a high exit beam such that the low exit beam and the high exit beam at least partially overlap in an overlap region on a projection plane
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
The invention describes an integral lighting assembly (1A, 1B, 1C, 1D, 1E) comprising an optical arrangement (2, 3); a first light source (S1) for generating a first beam (L1) of light; a first collimator (C1) for directing the first beam (L1) at the optical arrangement (2, 3); a second light source (S2) for generating a second beam (L2) of light; and a second collimator (C2) for directing the second beam (L2) at the optical arrangement (2, 3), wherein the optical arrangement (2, 3) is realized to manipulate the first and second light beams (L1, L2) to give a first exit beam (BLO) and a second exit beam (BRI) such that the first exit beam (BLO) and the second exit beam (BRI) are partially combined in an overlap region (44) on a projection plane (4) located at a predefined distance from the integral lighting assembly (1A, 1B, 1C, 1D, 1E). The invention further describes an automotive headlamp arrangement (12) comprising such an integral lighting assembly (1A, 1B, 1C, 1D, 1E).