LED Retrofit Lamp Centering Ring Alignment for Headlight Beam Compliance
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Solution Overview
Problem
LED retrofit lamps face challenges in replicating the light emission pattern and mechanical fit of conventional lamps, leading to suboptimal beam shapes and glare issues due to their bulkier size and different angular radiation patterns, which are not fully compliant with existing vehicle headlight reflector designs and regulations.
Innovation Solution
The LED retrofit lamp employs a centering ring with alignment features that define a mounting position and tolerance box, allowing the light emitting area to be positioned such that its base-side end is at least 0.1 mm from the tolerance box base-side end and the top-side end is at most 1.5 mm from the tolerance box top-side end, optimizing the axial position to match the virtual light emitting area within the reflector's tolerance box, thereby improving beam shaping and compliance with regulatory requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If LED retrofit lamps are designed to fit conventional lamp sockets, then they can replace existing lamps, but their bulkier size and different radiation pattern cause suboptimal beam shapes and glare issues
Solution Approach 1:
The patent applies local quality by creating a virtual light emitting area through optical elements (lens or reflector) that is positioned and shaped to match the specific requirements of the tolerance box, while the physical LED structure can have different dimensions. The optical elements are designed to concentrate and redirect light from the LED chip to create a virtual emission area with precise spatial characteristics, enabling local optimization of light distribution without changing the overall lamp form factor.
Solution Approach 2:
The patent uses copying by creating a virtual light emitting area that replicates the ideal light source position and characteristics required by conventional headlight systems. The optical elements generate this virtual image of the light source within the tolerance box, effectively copying the desired light emission pattern without requiring the physical LED to be positioned or shaped exactly like traditional filaments.
2Manufacturing precision
If the LED light emitting area is positioned within the tolerance box, then beam shaping improves, but the bulkier LED structure makes precise positioning difficult
Solution Approach 1:
The patent introduces optical elements (lens or reflector) as intermediaries between the physical LED chip and the required virtual light emitting area. These optical elements act as mediators that transform the light from the LED chip, which can be positioned more flexibly, into the desired virtual image position within the tolerance box. This allows decoupling of the physical LED positioning from the virtual light source positioning requirements.
Solution Approach 2:
The patent applies dimensionality change by using optical elements to create a virtual image in a different spatial dimension than the physical LED chip. The optical system transforms the three-dimensional position of the LED chip into a virtual image position that satisfies the tolerance box requirements, effectively adding an optical dimension to the positioning problem.
3Duration of action of stationary object
If conventional lamps are replaced with LED retrofits, then energy efficiency and lifetime improve, but compliance with existing headlight reflector designs and regulations is compromised
Solution Approach 1:
The patent applies parameter changes by precisely controlling the position, size, and shape parameters of the virtual light emitting area to match regulatory requirements. The optical elements are designed to transform the LED light output into a pattern that satisfies ECE beam requirements, adjusting parameters such as light distribution angles, intensity profiles, and cutoff patterns to ensure compliance while maintaining LED advantages.
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 enables LED retrofits to produce beam shapes comparable or superior to conventional lamps, ensuring compliance with ECE beam requirements and reducing glare, while maintaining low junction temperatures and efficient heat management.
Implementation Method 1
An LED retrofit lamp includes a centering ring with alignment features, which define: a mounting position of the lamp within a vehicle reflector, a reference axis, a reference direction along the reference axis from a base to a top end of the lamp, and a tolerance box intersecting the reference axis and extending axially along the reference direction from a tolerance box base-side end to a tolerance box top-side end. The lamp also includes an arrangement that emits light transversal to the reference axis
Data Source
AI summary
An LED retrofit lamp includes a centering ring with alignment features, which define: a mounting position of the lamp within a vehicle reflector, a reference axis, a reference direction along the reference axis from a base to a top end of the lamp, and a tolerance box intersecting the reference axis and extending axially along the reference direction from a tolerance box base-side end to a tolerance box top-side end. The lamp also includes an arrangement that emits light transversal to the reference axis and has a light-emitting area that extends axially from an LED base-side end to an LED top-side end. The LED base-side end has an axial distance of at least 0.1 mm from the tolerance box base-side end in the reference direction, and the LED top-side end has an axial distance of at most 1.5 mm from the tolerance box top-side end in the reference direction.