Patent Application
20150308646
This application claims the benefit of priority based on Taiwan Patent Application No 103134681, filed on Oct. 6, 2014, the contents of which are incorporated herein by reference in their entirety.
1. Field of the Invention
The present invention is related to a light source module and a light-emitting diode (LED) array for the light source module; and more particularly, the present invention is related to an LED array for a light source module and a light source module complying with vehicle lighting regulations.
2. Descriptions of the Related Art
Headlights in motor vehicles are mainly used at night or in harsh environments for road lighting. In conventional vehicle headlights, halogen lamps or high intensity discharge (HID) lamps are commonly provided as the light source. In an HID lamp, light is generated by a discharge phenomenon that occurs between two metal electrodes respectively disposed at both ends of the HID lamp. Thus, compared to halogen lamps, HID lamps have higher lumen output, better luminous efficacy, and longer lifetime. However, the lifetime of an HID lamp is generally only several hundred or several thousand hours. Therefore, seeking a new durable light source to replace conventional lamps for higher lumen output, better luminous efficacy, and longer lifetime is a need for new motor vehicles.
With the development of integrated circuit (IC) design, semiconductor manufacturing, and photovoltaic technology, LED is a new type of solid-state light source in the 21st century. Compared to halogen lamps or HID lamps, LED lamps have smaller size, higher lumen output, better luminous efficacy, lower power consumption, and longer lifetime. However, the optical, the thermal, and the electrical designs of new LED lamps are different from those of halogen lamps or HID lamps. Automobile manufacturers have to reconsider different design rules for headlights with LED lamps during developing new motor vehicles. For example, the detailed designs of an LED headlight complying with vehicle lighting regulations are shown and described in U.S. Pat. No. 7,645,062, filed on Mar. 25, 2004 and entitled “Light Source and Vehicle Lamp.”
Moreover, as to existing motor vehicles having conventional headlights with halogen lamps or HID lamps, it is hard to directly utilize an LED lamp of a new headlight to replace a halogen lamp or an HID lamp of an original headlight due to different architectures between the original headlight and the new headlight. As a result, consumers will attenuate will of replacing the halogen lamp or the HID lamp with the LED lamp.
In view of this, it is important to provide an LED light source which can directly replace a light source of a halogen lamp or an HID lamp, such that the consumer can replace the light source of the halogen lamp or the HID lamp with the LED light source rapidly and precisely.
An objective of the present invention is to provide an LED array for a light source module. The light source module comprises a substrate.
To achieve the aforesaid objective, the LED array of the present invention comprises a first LED sub-array, at least one second LED sub-array, and at least one third LED sub-array. The first LED sub-array emits a first light beam. The at least one second LED sub-array emits a second light beam. The at least one third LED sub-array is disposed between the first LED sub-array and the at least one second LED sub-array, and emits a third light beam. The first LED sub-array, the at least one second LED sub-array, and the at least one third LED sub-array are substantially disposed on the substrate along a horizontal axis. The first light beam, the second light beam, and the third light beam jointly form a light area. Luminance of the third light beam is less than luminance of the first light beam or luminance of the second light beam.
Another objective of the present invention is to provide a light source module which comprises a substrate and an LED array. The LED array has a plurality of LED chips. The LED chips are substantially disposed on the substrate along a horizontal axis. Distances between each two adjacent LED chips of the LED array are substantially different from each other.
Yet a further objective of the present invention is to provide a light source module which comprises a substrate and an LED array. The LED array is disposed on the substrate and emits a light beam for forming a light area. The light area has an effective horizontal width which is substantially from 6 millimeter (mm) to 18 mm.
Another further objective of the present invention is to provide a light source module which comprises a substrate, an LED array, and a protruding structure. The protruding structure is disposed on the substrate and surrounding the LED array. The LED array is disposed on the substrate and emits a light beam forming a non-rectangular light area via the protruding structure.
According to the above description, the light source module and the LED array for the light source module according to the present invention provide a light source complying with vehicle lighting regulations and architectures of original headlights in motor vehicles. Accordingly, the light source module and the LED array for the light source module according to the present invention can effectively overcome the problem of the prior art that, consumers will attenuate will of replacing the halogen lamp or the HID lamp with the LED lamp.
The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.
In the following description, this invention will be explained with reference to embodiments thereof. However, the description of these embodiments is only for purposes of illustration rather than limitation. It should be appreciated that in the following embodiments and attached drawings, elements unrelated to this invention are omitted from depictions; and dimensional relationships among individual elements in the attached drawings are illustrated only for ease of understanding, but not to limit the actual scale.
In one embodiment, the substrate 131 is made of heat conductive material for increasing cooling efficiency of the LED array 135. For example, the substrate 131 can be made of aluminum, copper, lead, tin, magnesium, zinc, steel, titanium, polymer, ceramic, or a combination of the aforesaid materials. The LED array 135 is made by chip-on-board (COB) package process. The detailed technical information of the LED package process can be referred to U.S. Pat. No. 7,732,233, filed on Jun. 10, 2009 and entitled “Method for making light emitting diode chip package,” and U.S. Pat. No. 8,129,206, filed on Jun. 9, 2009 and entitled “Light emitting diode package and method of making the same,” which are herein incorporated by reference.
More specifically, the first LED sub-array 135a disposed on the central area 131a of the substrate 131 emits a first light beam (not shown). The second LED sub-arrays 135b are respectively disposed on the side areas 131b of the substrate 131. Each of the second LED sub-arrays 135b emits a second light beam (not shown). The third LED sub-arrays 135c are respectively disposed on the third areas 131c of the substrate 131. Each of the third LED sub-arrays 135c emits a third light beam (not shown). The first LED sub-array 135a, the second LED sub-arrays 135b, and the third LED sub-arrays 135c are substantially disposed on the substrate 131 along a horizontal axis X.
As shown in
The LED chip can be a horizontal-type LED chip, a vertical LED chip, or a flip LED chip. In one embodiment, the first LED sub-array 135a has six LED chips. Each of the second LED sub-arrays 135b has two LED chips. Each of the third LED sub-arrays 135c has a LED chip. However, in other embodiments, the first LED sub-array 135a, the second LED sub-arrays 135b, and the third LED sub-arrays 135c can individually have different number of LED chip. It should be noted that the first LED sub-array 135a is not limited to have six LED chips in the embodiment. Similarly, it should be noted that each of the second LED sub-arrays 135b is not limited to have two LED chips in the embodiment. It should be also noted that each of the third LED sub-arrays 135c is not limited to have a LED chip. Each of the LED chips of the first LED sub-array 135a, the second LED sub-arrays 135b, and the third LED sub-arrays 135c has an area. The areas of the LED chips are approximately the same.
Accordingly, luminance of the third light beam emitted by one of the third LED sub-arrays 135c is less than luminance of the first light beam emitted by the first LED sub-array 135a or luminance of the second light beam emitted by one of the second LED sub-arrays 135b.
There is a first distance D1 between the first LED sub-array 135a and the third LED sub-array 135c next to the first LED sub-array 135a. There is a second distance D2 between the second LED sub-array 135b and the third LED sub-array 135c next to the second LED sub-array 135b. Accordingly, there is the first distance D1 between the LED chip of the first LED sub-array 135a and the LED chip of the third LED sub-array 135c next to the LED chip of the first LED sub-array 135a. There is the second distance D2 between the LED chip of the second LED sub-array 135b and the LED chip of the third LED sub-array 135c next to the LED chip of the second LED sub-array 135b. In one embodiment, the first distance D1 or the second distance D2 is substantially from 50 micrometer (μm) to 900 μm. The second distance D2 is greater than the first distance D1. However, in other embodiments, the second distance D2 can be less than or equal to the first distance D1. It should be noted that the second distance D2 is not limited to be greater than the first distance D1.
More specifically, each of the distances between each two adjacent LED chips of the first LED sub-array 135a is substantially from 50 μm to 150 μm. Similarly, each of the distances between each two adjacent LED chips of each of the second LED sub-arrays 135b is substantially from 50 μm to 150 μm. In one embodiment, the distances between each two adjacent LED chips of the first LED sub-array 135a or each of the second LED sub-arrays 135b are less than the first distance D1 or the second distance D2.
The protruding structure 133 which surrounds the LED array 135 is used for supporting the fluorescent layer 137. The protruding structure 133 has a height substantially from 0.5 mm to 1.5 mm. Accordingly, the fluorescent layer 137 disposed on the LED array 135 has an effective horizontal width H substantially from 6 mm to 18 mm. The first light beam emitted by the first LED sub-array 135a, the second light beams emitted by the second LED sub-arrays 135b, and the light beams emitted by the third LED sub-arrays 135c are mixed through the fluorescent layer 137 to form the aforesaid light beam emitted by the light source module 13. The light beam emitted by the light source module 13 mixed by the first light beam, the second light beams, and the third light beams forms a light area with the effective horizontal width H substantially from 6 mm to 18 mm according to a shape of the protruding structure 133 and a shape of the fluorescent layer 137 corresponding to the shape of the protruding structure 133.
In one embodiment, the light beam emitted by the light source module 13 mixed by the first light beam, the second light beams, and the third light beams forms a non-rectangular light area according to the shape of the protruding structure 133 and the shape of the fluorescent layer 137. However, in other embodiments, the light beam emitted by the light source module 13 mixed by the first light beam, the second light beams, and the third light beams can form different kinds of light areas according to different shapes of the protruding structure 133 and the fluorescent layer 137. It should be noted that the light area formed by the light beam is not limited to be a non-rectangular light area.
According to the above description, the LED array 135 of the light source module 13 has the light area with the effective horizontal width H substantially from 6 mm to 18 mm. The light area of the LED array 135 of the light source module 13 has a central area, two side areas, and two third areas respectively corresponding to the central area 131a, the side areas 131b, and the third areas 131c of the substrate 131. More specifically, the first light beam emitted by the first LED sub-array 135a of the LED array 135 forms the central area of the light area. The second light beams emitted by the second LED sub-arrays 135b respectively form the side areas of the light area. The third light beams emitted by the third LED sub-arrays 135c respectively form the third areas of the light area.
According to the above description, the luminance of the third light beam emitted by one of the third LED sub-arrays 135c is less than the luminance of the first light beam emitted by the first LED sub-array 135a or the luminance of the second light beam emitted by one of the second LED sub-arrays 135b. Thus, luminance of the central area of the light area is greater than luminance of one of the third areas of the light area. Luminance of one of the side areas of the light area is greater than the luminance of one of the third areas of the light area.
As shown in
More specifically, the central area of the light area formed by the first LED sub-array 135a forms a central illumination area 41a of the illumination area 4 on the projection plane with the distance of 25 meters ahead of the vehicle headlight through the shutter. The side areas of the light area formed by the second LED sub-arrays 135b respectively form two side illumination areas 41b of the illumination area 4 on the projection plane with the distance of 25 meters ahead of the vehicle headlight through the shutter. The third areas of the light area formed by the third LED sub-arrays 135c respectively form two third illumination areas 41c of the illumination area 4 on the projection plane with the distance of 25 meters ahead of the vehicle headlight through the shutter. The third illumination areas 41c partly individually overlap the central illumination area 41a. Simultaneously, the third illumination areas 41c partly respectively overlap the side illumination areas 41b.
According to the above description, the luminance of the central area of the light area or the luminance of one of the side areas of the light area is greater than the luminance of one of the third areas of the light area. A number of the LED chips of the first LED sub-array 135a is greater than a number of the LED chips of one of the second LED sub-arrays 135b or a number of the LED chips of one of the third LED sub-arrays 135c. The number of the LED chips of one of the second LED sub-arrays 135b is greater than the number of the LED chips of one of the third LED sub-arrays 135c. Thus, luminance of the central illumination area 41a is greater than luminance of one of the third illumination areas 41c. Luminance of one of the side illumination areas 41b is greater than the luminance of one of the third illumination areas 41c. An area of the central illumination area 41a is greater than an area of one of the third illumination areas 41c. An area of one of the side illumination areas 41b is greater than the area of one of the third illumination areas 41c.
Each of the second LED sub-arrays 151b has four LED chips substantially symmetrically disposed on each of the side areas 131b of the substrate 131 along the horizontal axis X and the vertical axis Y. Luminance of a second light beam emitted by one of the second LED sub-arrays 151b of the light source module 15 is greater than the luminance of the second light beam emitted by one of the second LED sub-arrays 135b of the light source module 13 due to increasing a number of the LED chips.
In addition to the aforesaid description, the embodiment of the light source module 15 can also execute all the operations and functions set forth in the embodiment light source module 13. How the light source module 15 executes these operations and functions will be readily appreciated by those of ordinary skill in the art based on the explanation of the light source module 13 and, thus, will not be further described herein.
The first LED sub-arrays 161a has four LED chips substantially symmetrically disposed on the central areas 131a of the substrate 131 along the horizontal axis X. Manufacturing cost of the light source module 16 is less than manufacturing cost of the light source module 13 due to decreasing a number of the LED chips.
In addition to the aforesaid description, the embodiment of the light source module 16 can also execute all the operations and functions set forth in the embodiment light source module 13. How the light source module 16 executes these operations and functions will be readily appreciated by those of ordinary skill in the art based on the explanation of the light source module 13 and, thus, will not be further described herein.
The first LED sub-array 171a has four LED chips substantially symmetrically disposed on the central area 131a of the substrate 131 along the horizontal axis X and the vertical axis Y. Each of the second LED sub-arrays 171b has four LED chips substantially symmetrically disposed on each of the side areas 131b of the substrate 131 along the horizontal axis X and the vertical axis Y. Each of the third LED sub-arrays 171c has two LED chips substantially symmetrically disposed on each of the third areas 131c of the substrate 131 along the horizontal axis X. A light source quality of the light source module 17 is better than a light source quality of the light source module 13 due to averaging a number of the LED chips between the first LED sub-array 171a, the second LED sub-arrays 171b, and the third LED sub-arrays 171c.
In addition to the aforesaid description, the embodiment of the light source module 17 can also execute all the operations and functions set forth in the embodiment light source module 13. How the light source module 17 executes these operations and functions will be readily appreciated by those of ordinary skill in the art based on the explanation of the light source module 13 and, thus, will not be further described herein.
The LED array 135 can be disposed on the substrate 131 in a specific pattern, for example, but not limited to, an L shape, an U shape, an H shape, an M shape, an N shape, or a ⊥ shape according to different arrangements of the first LED sub-arrays 135a, 161a, 171a, the second LED sub-arrays 135b, 151b, 171b, and the third LED sub-arrays 135c, 171c. The detailed designs of the LED arrays can be referred to U.S. Design patent application No. 29/471,507, filed on Nov. 1, 2013 and entitled “Light Emitting Diode Device,” China Design patent application No. 201330532498.2, filed on Nov. 7, 2013 and entitled “Light Emitting Diode Device,” and Taiwan Design patent application No. 103301434, filed on Mar. 14, 2014 and entitled “Portion of Light Emitting Diode Device,” which are herein incorporated by reference.
According to the above description, the light source module and the LED array for the light source module provide a light source complying with vehicle lighting regulations and architectures of original headlights in motor vehicles. Accordingly, the light source module and the LED array for the light source module according to the present invention can effectively overcome the problem of the prior art that, consumers will attenuate will of replacing the halogen lamp or the HID lamp with the LED lamp.
The above embodiments merely give the detailed technical contents of the present invention and inventive features thereof, and are not to limit the covered range of the present invention. People skilled in this field may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended.
| Number | Date | Country | Kind |
|---|---|---|---|
| 103134681 | Oct 2014 | TW | national |
This application claims the benefit of Provisional Application Ser. No. 61/969,441 filed on Mar. 24, 2014.
| Number | Date | Country | |
|---|---|---|---|
| 61969441 | Mar 2014 | US |
