LED Headlight Collimation and Mixing Optics for Beam Angle Control
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Solution Overview
Problem
Existing LED headlights face challenges in achieving a wide adjustment range of the half beam angle while maintaining homogeneous light distribution, with current solutions either resulting in a hard light source in flood settings or a soft light source in spot settings, but not both effectively.
Innovation Solution
The proposed LED lamp design features a light source composed of multiple LEDs with collimation optics that include conical total reflection lenses and stepped Fresnel lenses, allowing for a wide adjustment range of the half beam angle by directing light beams to fill the light entry surface of the mixing optics, which then mixes and emits light with a predetermined distribution, and includes a combination of angle-deflecting and straight-emitting collimation optics with reflective elements to optimize light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the light source is positioned close to the field optics to create a hard light source in flood setting, then the luminous efficacy is improved, but the light field becomes too focused and cannot provide soft tapering in spot setting
Solution Approach 1:
The light source is segmented into multiple individual LEDs arranged in a specific pattern rather than using a single consolidated light source. This segmentation allows different portions of the light source to be positioned at different distances from the field optics, enabling both hard and soft light characteristics to be achieved in different operating modes.
Solution Approach 2:
The patent transitions from a single-point light source to a distributed array of LEDs in multiple dimensions. By arranging LEDs at different positions and distances from the field optics, the system gains additional spatial degrees of freedom to control light distribution characteristics for both flood and spot settings.
2Adaptability or versatility
If the light source is positioned far from the field optics to create a soft light source in spot setting, then the beam angle adjustment is improved, but the luminous efficacy decreases and light distribution becomes less concentrated
Solution Approach 1:
The light source is divided into multiple LED elements that can be independently positioned. LEDs intended for spot lighting can be placed farther from the field optics to create soft, wide beam angles, while LEDs for flood lighting remain closer to maintain high luminous efficacy and concentrated light distribution.
Solution Approach 2:
Different regions of the light source array are assigned different spatial characteristics. LEDs in certain positions are optimized for flood lighting with high efficacy, while LEDs in other positions are optimized for spot lighting with soft beam edges, allowing each local region to have the quality needed for its specific function.
3Device complexity
If a single light source configuration is used, then the device complexity is reduced, but the ability to provide both hard and soft light characteristics in different settings is lost
Solution Approach 1:
The light source configuration is made dynamically adjustable through the selective activation of different LED elements based on the desired operating mode. The system can dynamically reconfigure which LEDs are active and at what intensity levels to achieve either hard or soft light characteristics as needed.
Solution Approach 2:
The multi-LED light source array serves multiple functions within a single configuration. The same array of LEDs can produce both hard light characteristics for flood lighting and soft light characteristics for spot lighting, eliminating the need for separate light source systems for different functions.
4Manufacturing precision
If the field optics diameter is increased to fill the entire light entry surface, then the light distribution uniformity is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The collimation optics perform preliminary action by pre-collimating or pre-shaping the light beams from individual LEDs before they reach the field optics. This preliminary light conditioning ensures that when light enters the field optics, it is already optimized for uniform distribution, reducing the complexity requirements of the field optics itself.
Solution Approach 2:
Collimation optics are introduced as intermediary elements between the LED light sources and the field optics. These intermediaries pre-process the light to achieve optimal characteristics for uniform distribution, allowing the field optics to be simpler in design while still achieving the desired uniform light distribution.
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 design enables a homogeneous, softly tapered light field in flood settings and a soft light source in spot settings, with improved light distribution and efficiency, allowing for precise adjustment of the beam angle without structural changes to the headlight.
Implementation Method 1
collimation optics has conical total reflection lenses on its light entry side, which are each arranged directly in front of an LED
Implementation Method 2
on its light exit side a stepped lens structure in the manner of a Fresnel lens and deflects the light beams emitted by the LEDs
Implementation Method 3
the downstream mixing optics are illuminated over the entire light entry surface and can optimally mix the light that is directed and bundled into a surface and incident from different directions
Implementation Method 4
the light beams emitted by the optical elements are directed onto a reflector, which throws the light beams back onto the mixing optics
Data Source
Figure 1
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Figure 4~5
AI summary
LED luminaire, particularly LED headlight, comprising an active light source (2) composed of a plurality of LEDs (21 to 26) that have the same color or different colors and are disposed on a flat or curved surface (20, 200) or circuit board, and an optical system comprising - a collimation optics unit (3), the individual lenses of which are disposed a small distance above the emission surfaces of the LEDs (21 to 26) and which collects and focuses the light (L1 to L4) emitted by the LEDs and directs it onto a surface, - a mixing optical unit (4), which receives the light (K1, K2, E) that has been directed onto a surface and focused and mixes it in terms of the color and/or brightness, - and a field optics unit (5), which receives the light (M1, M2 or N1, N2) emitted by the mixing optics unit (4) and emits it with predetermined light distribution(F1-F4) to the far field.