The present disclosure relates generally to lighting for motor vehicles. More specifically, the present disclosure relates to headlights for passenger vehicles, such as cars and trucks.
Headlight assemblies for vehicles are subject to regulations regarding a cut-off pattern in order to illuminate a roadway ahead of the vehicle while also minimizing disruption to drivers of other vehicles, including oncoming traffic and vehicles traveling ahead of and in a same direction as the subject vehicle. Several different regulations and standards for headlight illumination may apply in different jurisdictions. Examples of such regulations and standards include ECE Created by the United Nations Economic Commission for Europe, United States Department of Transportation (DOT) for use in the U.S. & Canada, CCC certification for China, and U.S. Society of Automotive Engineers (SAE) standards.
Adaptive driving beam (ADB) headlights and systems may provide enhanced automatic control of the headlamps of a vehicle, dimming the headlights in response to a detection of light (such as headlamps of oncoming vehicles and/or taillights of leading vehicles) in the region forward of the vehicle.
The present disclosure provides a lighting assembly for a vehicle headlight. The lighting assembly 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.
The present disclosure also provides a lighting assembly for a vehicle headlight. The lighting assembly includes: a plurality of discrete LED devices, each defining an output surface having a polygon shape, the output surfaces together defining a layout arrangement with substantially continuous illumination and with a shape corresponding to a predetermined illumination pattern; a shield 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 the predetermined illumination pattern with a contoured shape; and an imaging lens assembly overlying the plurality of discrete LED devices and the shield. The imaging lens assembly is 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.
These and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims, and the accompanying figures.
Further details, features and advantages of designs of the invention result from the following description of embodiment examples in reference to the associated drawings.
Referring to the drawings, the present invention will be described in detail in view of following embodiments.
As shown in
The low-beam light lighting assemblies 22 of the two headlight assemblies 20a, 20b function together to produce a low-beam illumination in accordance with a first predetermined illumination pattern 14. The first predetermined illumination pattern may be determined in accordance with regulatory requirements and/or in accordance with requirements set forth by an original equipment manufacturer (OEM). For example,
The ADB lighting assembly 32 includes a first ADB light source 34 and an ADB lens assembly 36 that overlies the First ADB light source 34 and which is configured to focus and direct light therefrom to produce an ADB lighting pattern. The ADB lens assembly 36 may include an imaging lens assembly that is arranged to produce the ADB lighting pattern in accordance with a predetermined illumination pattern that is generated by the ADB light source.
Each of the headlight assemblies 20a, 20b also includes a controller 40 in communication with each of the low-beam light source 24, and the first ADB light source 34. The controller 40 may also be called a headlamp smart lighting driver or a headlamp smart LED driver. The controller 40 may be configured to control a pattern of light generated by the first ADB light source 34. In some embodiments, the controller 40 may control operation of the low-beam light source 24. For example, the controller 40 may provide an on/off signal to a switching device to control the low-beam light source 24. Alternatively or additionally, the controller 40 may control a brightness level of the low-beam light source 24. In some embodiments, the controller 40 may control a light distribution output of the first ADB light source 34, such as a beam pattern generated by the first ADB light source 34.
The controller 40 includes a processor 42 coupled to a storage memory 44. The storage memory 44 includes instruction storage 46 storing instructions, such as program code for execution by the processor 42. The storage memory 44 also includes data storage 48 for holding data for use by the processor 42.
The output surfaces 55, together, define a layout arrangement 58 with substantially continuous illumination and with a shape that corresponds to the predetermined illumination pattern. For example, as shown in
For simplicity of illustration, only one of the discrete LED devices 54 shown on
Each of the discrete LED devices 54 may be individually controllable to produce an intensity of light in accordance with the predetermined illumination pattern. For example, the ADB lighting assembly 32 may be operated with each of the discrete LED devices 54 having a first predetermined brightness level, with different ones of the discrete LED devices 54 operated to produce different intensities of light in order to generate the second predetermined illumination pattern 16. Each of the discrete LED devices 54 may also be individually controllable to operate in a reduced intensity mode to produce a dimmed region of the lighting pattern. For example, a group of one or more of the discrete LED devices 54 may be operated in the reduced intensity mode to produce a dimmed region corresponding to a direction of oncoming traffic in order to reduce the intensity of light being directed toward that oncoming traffic.
The layout arrangement 58 may be inverted relative to the predetermined illumination pattern. For example, the layout arrangement 58 may include the triangular pattern with a flat top and progressively narrowing to a smallest width at a bottom row, which may be inverted by the ADB lens assembly 36 to produce the predetermined illumination pattern with a flat bottom, narrowing to a smallest width at the top.
The First ADB light source 34 also includes three LED drivers 56 mounted on the surface 52 of the PCB 50, with each of the LED drivers 56 configured to supply power to sixteen (16) of the discrete LED devices 54. Thus, the three (3) LED drivers 56 may be fully utilized for powering the forty-eight (48) of the discrete LED devices 54.
As shown in
The ADB lens assembly 36 also includes a third lens element 80 overlying the second lens element 70, with the second lens element 70 disposed between the third lens element 80 and the first lens element 60. The third lens element 80 defines a third input surface 82 receiving light from the second output surface 74 of the second lens element 70. The third lens element 80 also defines a third output surface 84 for outputting light. As shown, the third input surface 82 and the third output surface 84 each have a convex shape. However, either or both of the third input surface 82 and the third output surface 84 may have a different shape.
In some embodiments, each of the lens elements 60,70,80 have at least one aspheric lensing surface. For example, some or all of the input surfaces 62, 72, 82 and/or some or all of the output surfaces 64, 74, 84 may be aspheric.
In some embodiments, at least two of the lens elements 60, 70, 80 are made of different materials, which may aid in reducing or preventing color separation of the light passing therethrough. In some embodiments, all three of the lens elements 60, 70, 80 are made of different materials. For example, the first lens element 60 may be made of glass, and the second lens element 70 and the third lens element 80 may each be made of different types of polymer material, such as polycarbonate (PC) and/or Poly(methyl methacrylate) (PMMA), also called acrylic. Glass material may enable the first lens element 60 to withstand relatively high temperatures produced by operation of the discrete LED devices 54 and the LED drivers 56. In some embodiments, the second lens element 70 may be made of polycarbonate (PC), and the third lens element 80 may be made of PMMA.
The second ADB light source 234 includes the shield 240 configured to define the contoured upper edge, in combination with a relatively low number of discrete LED devices 54. This combination may provide a lighting effect with one or more smooth contoured edges, and without rough or jagged edges that may otherwise be created by a relatively low number of discrete LED devices 54. This combination may provide a significant cost savings over alternative designs that may require substantially more and/or smaller LED devices to achieve a similar contoured edge.
The shield 240 may be made of metal, such as stainless steel or aluminum, although other types of materials may be used. In some embodiments, the shield 240 may be non-reflective on either or both of a back surface that faces toward the discrete LED devices 54 and/or a front surface that faces outwardly, away from the discrete LED devices 54. In some embodiments, the shield 240 may reflect no more than 10% of incident light. In some embodiments, the shield 240 may reflect no more than 5% of incident light. In some embodiments, the shield 240 may have a non-reflective coating, such as paint, a powder coating, and/or an anodized layer. In some embodiments, the shield 240 may be made of aluminum that is anodized to be non-reflective. In some embodiments, a sheet of anodized aluminum may be used to form the shield 240. For example, pre-anodized aluminum may be stamped and bent to form the shield 240. However, other techniques may be used in making the shield 240, such as anodizing and/or other coating applied to a metal substrate before or after the metal is formed to shape the shield 240.
The shield 240 is configured as a surface-mount device (SMD) that is attached to the surface 52 of the PCB 50 by soldering. However, the shield 240 may have a different configuration and be attached to the PCB 50 by other means, such as by clips or pins that pass through the PCB or engage an edge thereof. In some embodiments, and as shown in
The system, methods and/or processes described above, and steps thereof, may be realized in hardware, software or any combination of hardware and software suitable for a particular application. The hardware may include a general purpose computer and/or dedicated computing device or specific computing device or particular aspect or component of a specific computing device. The processes may be realized in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable device, along with internal and/or external memory. The processes may also, or alternatively, be embodied in an application specific integrated circuit, a programmable gate array, programmable array logic, or any other device or combination of devices that may be configured to process electronic signals. It will further be appreciated that one or more of the processes may be realized as a computer executable code capable of being executed on a machine readable medium.
The computer executable code may be created using a structured programming language such as C, an object oriented programming language such as C++, or any other high-level or low-level programming language (including assembly languages, hardware description languages, and database programming languages and technologies) that may be stored, compiled or interpreted to run on one of the above devices as well as heterogeneous combinations of processors processor architectures, or combinations of different hardware and software, or any other machine capable of executing program instructions.
Thus, in one aspect, each method described above and combinations thereof may be embodied in computer executable code that, when executing on one or more computing devices performs the steps thereof. In another aspect, the methods may be embodied in systems that perform the steps thereof, and may be distributed across devices in a number of ways, or all of the functionality may be integrated into a dedicated, standalone device or other hardware. In another aspect, the means for performing the steps associated with the processes described above may include any of the hardware and/or software described above. All such permutations and combinations are intended to fall within the scope of the present disclosure.
The foregoing description is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This U.S. utility patent application claims the benefit of U.S. Provisional Patent Application No. 63/543,840 filed Oct. 12, 2023 and U.S. Provisional Patent Application No. 63/557,015, filed Feb. 23, 2024, the contents of which are incorporated herein by reference in their entirety.
Number | Date | Country | |
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63543840 | Oct 2023 | US | |
63557015 | Feb 2024 | US |