PCB-Mounted Headlight Shield for ADB Cut-Off Glare Control
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Solution Overview
Problem
Existing vehicle headlight assemblies struggle to meet regulatory requirements for cut-off patterns that minimize disruption to oncoming and preceding traffic while providing enhanced illumination, particularly with adaptive driving beam (ADB) systems.
Innovation Solution
A lighting assembly featuring a PCB-mounted shield and imaging lens system that includes discrete LED devices with controllable intensity and a shield defining a contoured edge, combined with an imaging lens assembly to produce a smooth, continuous illumination pattern that adheres to regulatory standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shield is added to define cut-off patterns, then glare to oncoming traffic is reduced, but device complexity increases
Solution Approach 1:
The patent combines the shield structure with the PCB mounting board, integrating the cut-off pattern definition function into the existing structural component. The shield is directly attached to the PCB and uses the same mounting infrastructure, merging two functions (structural support and light pattern definition) into a single integrated assembly, thereby reducing overall device complexity while maintaining glare reduction effectiveness.
Solution Approach 2:
The PCB-mounted shield serves multiple functions simultaneously: it provides structural support as part of the mounting system, defines the cut-off illumination pattern edges, and acts as a light-blocking element to prevent glare. This multi-functionality reduces the need for separate components, addressing the complexity issue while achieving the glare reduction goal.
2Ease of manufacture
If discrete LED devices are used to create continuous illumination, then manufacturing flexibility is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a lens assembly as an intermediary element between the discrete LED devices and the illumination target. The lens optically combines the light from multiple discrete LEDs to create a continuous illumination pattern, masking the discrete nature of the individual LED placements. This allows greater manufacturing flexibility in LED positioning while maintaining the appearance and functionality of continuous illumination.
Solution Approach 2:
The patent utilizes optical parameters (lens focal length, curvature, and positioning) to transform the discrete light sources into a continuous illumination pattern. By changing the optical parameters of the lens system, the apparent continuity of illumination is achieved regardless of the discrete LED spacing, thereby reducing the stringency of manufacturing precision requirements for LED placement.
3Reliability
If a contoured shield edge is used to define illumination pattern, then regulatory compliance is improved, but device complexity increases
Solution Approach 1:
The patent segments the shield structure into a standardized PCB-mounted component with integrated contoured edges. Rather than creating a completely custom complex shape, the shield is designed as a modular component that can be attached to standard PCB configurations, breaking down the complex contoured edge requirement into manageable geometric segments that are easier to manufacture while still achieving regulatory compliance.
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
The solution effectively produces a lighting pattern that meets regulatory requirements, reducing glare for oncoming and preceding vehicles while maintaining high-beam functionality, with potential cost savings and improved aesthetic design.
Implementation Method 1
an imaging lens assembly overlying the plurality of discrete LED devices and configured to focus and direct light from the plurality of discrete LED devices to produce a lighting pattern
Implementation Method 2
imaging lens assembly configured to focus and direct light
Data Source
AI summary
A lighting assembly for a vehicle headlight includes: a printed circuit board (PCB) defining a surface; a plurality of discrete LED devices disposed on the surface of the PCB and each defining an output surface, the output surfaces together defining a layout arrangement with substantially continuous illumination; a shield directly attached to the PCB and overlying the output surface of at least one discrete LED device of the plurality of discrete LED devices and to define at least one edge of a predetermined illumination pattern; and an imaging lens assembly overlying the plurality of discrete LED devices and configured to focus and direct light from the plurality of discrete LED devices to produce a lighting pattern in accordance with the predetermined illumination pattern.