Patent Application
20060262551
The present invention relates generally to reflectors for light sources used in automotive applications, and more particularly relates to trough reflectors for LED light sources.
Modern automotive light modules typically use a filament bulb as their light source. While such modules have a long and successful history, filament bulbs consume a large amount of power and have a relatively short life. In an attempt to overcome these shortcomings, others have proposed to utilize LED light sources to replace the filament bulbs since LED's consume significantly less power and have a long life span.
Unfortunately, LED solutions also have their drawbacks. In particular, automotive light assemblies utilizing LED light sources typically use a large number LED's, typically eight or more, which thus requires increasing amounts of power over a single LED bulb. Furthermore, these light modules using LED light sources suffer from poor efficiency, that is, the amount of original light from the light source which is actually directed outwardly away from the vehicle to illuminate the surrounding area.
In some applications, trough reflectors have been used for LED light sources. However, these reflectors usually result in a wider horizontal spread of the light beam than is required or desired. While side walls have been proposed to cut down on the horizontal spread, such reflectors overly constrain the light distribution. Furthermore, the use of side walls results in wasted light which is beyond the driver's field of vision. Additionally, the light collection efficiency of the trough reflector depends on its width, and the wider the trough the more horizontal the spread. Likewise, to collect a sufficient amount of light for a given width of the trough, numerous LED's must be placed at regular intervals along the trough axis. The use of multiple LED's increases the horizontal spread even further and also increases the amount of power consumed and the heat which must be dissipated.
Accordingly, there exists a need to provide a light assembly and trough reflector for a motor vehicle which can collect a sufficient amount of light, preferably from a single LED, while at the same time providing control over the horizontal spread as well as other beam pattern characteristics.
One embodiment of the present invention provides a reflector for redirecting light from a light source in a motor vehicle along a longitudinal axis. The reflector generally includes a first parabolic trough, a second parabolic trough, and third trough. The first and second parabolic troughs define first and second trough axes. The third trough has a third trough axis. The first and second parabolic troughs are positioned on opposing sides of the third trough. The first and second trough axes are angled relative to the third trough axis. In this manner, a reflector is provided which collects and reflects a sufficient amount of light while providing control over the beam pattern spread, particularly in the horizontal direction, whereby a single LED may be employed such that constraints imposed by heat dissipation are eliminated.
According to more detailed aspects, the first and second trough axes are angled in the range of 5 degrees to 45 degrees relative to the third trough axis. The third trough axis is generally perpendicular to the longitudinal axis. The third trough may be parabolic trough, or alternately may follow a complex curvature. Forming the third trough with a complex curvature permits increased control over the beam spread pattern and the creation of “hot spots”. The third trough may include a plurality of facets and most preferably includes two side facets connected to opposite sides of a center facet. In this case, the two sided facets are angled relative to the center facet, and each of the facets extend from an upper edge to the lower edge of the third trough.
Another embodiment of the present invention provides a light assembly for a motor vehicle which generally comprises a single LED light source and an embodiment of the reflector described above.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
Turning now to the figures,
As best seen in
In order to control the beam pattern spread and to prevent excess horizontal spread, the first and second parabolic troughs 32, 34 are angled relative to the third trough 36. As best seen in
It can therefore be seen that the first and second trough axes 42, 44 are rotated relative to the third trough axis 36. In the present embodiment, the first and second troughs have been rotated about 23 degrees relative to the third trough 36, but the angle of rotation is preferably in the range of 5 degrees to 45 degrees depending on the beam spread requirements. Likewise, angles of rotation for the first and second troughs 32, 34 outside of this range may be utilized for other lighting applications which require such beam spread characteristics. Preferably, the first trough 32 and second trough 34 are rotated identical amounts and thus represent mirror images of each other relative to the longitudinal axis 10, although it will be recognized that varying angles of rotation may be used depending on the particular application and beam spread requirements. Generally, the troughs 32, 34, 36 are connected along seams 38, 40. The first and second troughs 32, 34 may be connected to the third trough 36 by any conventional means, such as by integrally and unitarily molding the reflector 30, welding, adhesives, mechanical attachment means such as fasteners, threaded fasteners, rivets, etc., and plastic welding techniques.
The focal lengths of the first, second and third parabolic troughs 32, 34, 36 may also be varied. For example, the first and second parabolic troughs 32, 34 have been depicted as having a focal length of about 12 mm, while the third parabolic trough 36 has a focal length of about 10 mm. The compound trough forming the reflector 30 is structured to have an overall width of about 40 mm and the height is limited to about 35 mm, although it will be recognized by those skilled in the art that numerous variations and the size may be employed depending on the particular application and beam spread requirements. As used herein, the focal length refers to the shortest distance between the focal point of the parabola and a surface of the particular reflector trough 32, 34, 36. With reference to
The structure of the trough 30 depicted in
An alternate embodiment of the reflector constructed in accordance with the teachings of the present invention has been depicted in
By forming the third and central trough 136 to follow a complex curvature (i.e. a numerically generated curve), a particular vertical collimation of the light may be generated. For example, the central trough 136 may not perfectly collimate the light and in fact may result in some beam spread or focus in the vertical direction. In this manner, the reflector 130 may be used to form a “hot spot”, which is known in the art and is preferable for certain lighting applications such as head lamps. By using parabolic troughs for the first and second troughs 132, 134 the same benefits are achieved as in the prior embodiment, such as limiting the horizontal spread and preventing redirection of light in the foreground area below the driver's field of vision, while at the same time providing control over the beam spread characteristics.
Yet another embodiment of a reflector 230 constructed in accordance with the teachings of the present invention has been depicted in
As with the embodiment depicted in
By using a complex curvature for the facets 238, 240, 242 and at the same time providing for variation in the rotation angle of the side facets 238, 240, excellent control over the beam spread characteristics is provided. As with the prior embodiments, utilizing parabolic troughs 232, 234 on opposing sides of the central trough 236 results in improved light collection, efficiency and reflectivity, while also providing better limitation of the horizontal spread and preventing the waste of light in the foreground area out of the driver's field of vision.
The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
