Segmented LED Headlamp Module for Sharp Light-Dark Boundary
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Solution Overview
Problem
Existing LED modules for vehicle headlights struggle to produce a sharp and optimal light-dark boundary with a significant light intensity gradient, as they often rely on a single LED per reflector, limiting the precision and flexibility in shaping the light distribution.
Innovation Solution
The LED module is designed such that multiple LEDs are assigned to reflector segments, with each LED interacting with multiple segments to create a sharp light-dark boundary by optimizing the shape of the reflector surfaces to direct light closer to the boundary, using paraboloidal shapes and mathematical algorithms to achieve precise light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single LED is assigned to each reflector, then the device complexity is reduced and manufacturing is simplified, but the manufacturing precision of the light-dark boundary deteriorates
Solution Approach 1:
The reflector surface is segmented into multiple zones, each optimized to work with specific LEDs. This allows multiple LEDs to be assigned to each reflector, with each LED illuminating a specific area in cooperation with its primarily assigned reflector segment, thereby achieving precise control over the light-dark boundary while maintaining manageable device complexity
Solution Approach 2:
Different segments of the reflector surface are designed with locally optimized properties. The reflection surfaces have a paraboloidal or paraboloidal-like shape with free form that can be calculated to deviate from a perfect paraboloid to achieve specific intensity distributions. This local optimization enables sharp light-dark boundaries by directing light precisely to the boundary area
2Illumination intensity
If multiple LEDs are assigned to each reflector, then the light intensity gradient at the light-dark boundary is improved, but the device complexity increases
Solution Approach 1:
The reflector is divided into multiple segments that can be primarily or secondarily assigned to different LEDs. This segmentation allows systematic management of the increased number of LEDs and enables precise control over light distribution, achieving high intensity gradients at the boundary while keeping the system organized and manageable
Solution Approach 2:
Reflector segments can serve multiple functions by being primarily assigned to one LED for boundary generation and secondarily assigned to other LEDs for additional illumination areas. This multi-functionality reduces the need for completely separate reflector sections for each LED, thereby controlling device complexity while achieving the desired light intensity gradient
3Manufacturing precision
If the reflection surface is optimized for a specific LED position, then the manufacturing precision of light distribution is improved, but the adaptability to different LED configurations deteriorates
Solution Approach 1:
The reflector surface is divided into multiple segments that can be independently optimized and assigned to different LEDs. This segmentation allows the system to adapt to different LED configurations by reassigning segments to different LEDs without requiring complete redesign, thereby maintaining both precision and adaptability
Solution Approach 2:
The assignment of reflector segments to LEDs is not fixed but can be dynamically adjusted. The patent allows for primary and secondary assignments that can be configured based on the specific LED positions and requirements, enabling the system to adapt to different LED configurations while maintaining precise light distribution through the optimized segment shapes
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 configuration allows for a sharper and more defined light-dark boundary with increased contrast, enabling better control over the light distribution, including horizontal and asymmetrical configurations, and the ability to adjust brightness dynamically for improved safety and visibility.
Implementation Method 1
the light emitted by the LEDs and reflected by the reflector segments primarily assigned to the LEDs
Implementation Method 2
the reflection surfaces of the reflectors have a paraboloidal or paraboloidal-like shape
Data Source
Figure 1~3
Figure 4a~5
Figure 6~8
AI summary
LED module (1) of a motor vehicle headlight for generating a dimmed light distribution with a horizontal light-dark boundary (15), the LED module (1) comprising two reflectors (2, 3) each subdivided into several segments (2-1, 2-2, 2-3; 3-1, 3-2, 3-3, 3-4) and at least two LEDs (4, 5, 6, 7, 8), wherein at least one LED (4, 5, 6, 7, 8) is assigned to each of the reflectors (2, 3). In order to generate a particularly sharp light-dark boundary (15), it is proposed that the light-dark boundary (15) of the light distribution be subdivided into several adjacent sections (B1, B2, B3, B4).The LED module (1) is configured such that each of the LEDs (4, 5, 6, 7, 8), in conjunction with a specific reflector segment (2-1, 2-2, 2-3; 3-1, 3-2, 3-3, 3-4) primarily assigned to the LED (4; 5; 6; 7; 8), illuminates an area of the light distribution that generates a specific section (B1, B2, B3, B4) of the light-dark boundary (15), and that the sum of all LEDs (4, 5, 6, 7, 8) and their respective primary reflector segments (2-1, 2-3; 3-2, 3-3) generates the entire light-dark boundary (15). (Figure 4a, 4b).