Segmented Reflector Lighting for Uniform Automotive LED Signatures

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing LED displays in the automotive industry face challenges in achieving the required brightness and uniformity for light signatures due to the need for high operating currents and close LED spacing, which results in a non-uniform image and increased weight.

Innovation Solution

A lighting device with a reflector element subdivided into segments, each with a dedicated light-emitting diode, where the reflector foot contacts the printed circuit board, blocking light between segments and diffusing light efficiently, allowing for a compact and robust design that meets brightness requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If LEDs are placed close together to achieve high resolution, then image quality improves, but manufacturing complexity and cost increase

Engineering Contradiction:

ImproveLED spacing precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The reflector element is divided into multiple segments, each corresponding to a light-emitting diode. Each segment includes a reflector foot that contacts the printed circuit board, creating distinct light paths and eliminating the need for extremely close LED spacing. This segmentation allows for easier manufacturing while maintaining image quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflector element acts as an intermediary between the LEDs and the optical panel. By introducing this intermediate optical component with segmented structure, the system achieves high resolution without requiring LEDs to be placed extremely close together, thus simplifying manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If LEDs are placed close together to achieve high resolution, then image quality improves, but the device becomes less robust

Engineering Contradiction:

ImproveLED spacing precisionVSAvoiddevice robustness

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflector feet provide structural support and pre-positioning for the reflector segments. This beforehand positioning ensures proper alignment and spacing without requiring extremely precise LED placement, thereby improving device robustness while maintaining image quality.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If reflector openings are closed off to improve structural integrity, then device robustness improves, but light reflection efficiency may decrease

Engineering Contradiction:

Improvedevice robustnessVSAvoidlight reflection efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The reflector feet are made opaque to block light laterally, while the upper portions of the reflector segments maintain high reflectivity. This local differentiation of optical properties ensures both structural integrity and light reflection efficiency in their respective regions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The reflector feet, which could be seen as blocking light paths, actually serve a beneficial function by preventing lateral light leakage between adjacent segments. This converts what might be considered a disadvantage (blocking light) into a benefit (improving contrast and preventing light contamination between segments).

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 enhances brightness and efficiency while maintaining a compact structure, achieving uniform lighting and satisfying legal brightness standards for automotive applications.

Implementation Method 1

the light from which is reflected by the segments of the reflector element

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

The reflector foot also diffuses the light from the light-emitting diode toward the optical panel, thus increasing the brightness of the lit segment

Methodology Applied

Scientific EffectLight diffusion: Scattering

Data Source

PatentUS12422118B2Lighting device, lighting system and motor vehicle

Publication Date: 2025.09.23 HELLA GMBH & CO KGAA

AI summary

A lighting device for a motor vehicle with a printed circuit board populated with numerous light-emitting diodes, an optical panel, and a reflector element between the printed circuit board and the optical panel. The reflector element is subdivided into numerous segments. Each light-emitting diode is dedicated to a segment, such that light emitted from the light-emitting diodes is reflected by the segments of the reflector element and passes through the optical panel. Each segment of the reflector element has a reflector foot. The reflector foot surrounds the respective light-emitting diode, and is in contact with the printed circuit board at a contact surface.