LED Lighting Device with Integrated Cut-Off Reflector
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Solution Overview
Problem
Existing vehicle headlight designs face challenges in achieving accurate positioning of the light shielding portion, leading to complex and costly production processes due to tight tolerances required for the cut-off element in LED lighting systems.
Innovation Solution
A lighting device where the base, made of a heat-conducting material like aluminum, incorporates a collimator reflector with a straight border line as the cut-off element, eliminating the need for a separate cut-off element and ensuring accurate positioning through mechanical reference elements, and an insert with reflective surfaces for precise mechanical and optical alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate light shielding portion is used to form the cut-off, then the cut-off can be formed, but the positioning accuracy deteriorates due to mounting tolerances
Solution Approach 1:
The patent merges the light shielding portion with the base structure, making the cut-off element an integral part of the base rather than a separate component. This eliminates the need for separate mounting of the cut-off element, thereby removing mounting tolerances and improving positioning accuracy while simplifying the production process
Solution Approach 2:
The base structure is designed to serve multiple functions: it provides mechanical support, forms the cut-off through its own structure, and eliminates the need for separate adjustment mechanisms. This multi-functionality reduces the number of components and simplifies the production process while maintaining high positioning accuracy
2Manufacturing precision
If tight tolerances are applied for cut-off element positioning, then positioning accuracy improves, but production complexity and cost increase
Solution Approach 1:
By integrating the cut-off element into the base structure, the patent eliminates the need for tight tolerances in separate component mounting. The cut-off is formed directly by the base geometry, which can be manufactured with standard tolerances, thereby simplifying the production process while maintaining high positioning accuracy
Solution Approach 2:
The cut-off geometry is built into the base structure during the base manufacturing process itself, before assembly. This preliminary formation of the cut-off eliminates the need for subsequent adjustment procedures and tight tolerance control during assembly, simplifying production while ensuring accurate positioning
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 simplifies production, reduces part count, and achieves high accuracy in light distribution with a clear cut-off, enhancing electromagnetic compatibility and reducing the tolerance chain for precise alignment in vehicle headlights.
Implementation Method 1
a base made out of a heat conducting material... the base can serve as a heat sink for heat generated in the LED lighting element
Implementation Method 2
a collimator reflector is provided, which may comprise a plurality of reflective surfaces... the first reflective surface is arranged so that it reflects light from the LED element
Data Source
Figure 1~2
Figure 3a~3c
Figure 4~5
AI summary
An LED module is described with a base 10 made out of a heat conducting material. An LED element (32) is arranged in a cavity (11) of the base. A collimator reflector (70) is formed by reflective surfaces (24, 64, 66a). Three of these reflective surfaces (66a, 66b, 64) are provided on a plastic insert (60) received in the cavity (11). A further reflective surface (24) is provided on the base (10) itself. This surface (24) has a straight border line (50). The collimator reflector (70) is arranged to reflect light from the LED (32) so that a cut-off (72) is formed by the straight border line (50). By thus integrating the cut-off, as the most critical optical element, into the base (10) itself, high accuracy is achieved.