The present application relates generally to vehicle lighting. More specifically, the present application relates to a non-incandescent light source for a vehicle.
One embodiment of the present application relates to a light source for a vehicle including a first substrate, a second substrate, a first light emitting element, and a second light emitting element. The second substrate is spaced apart from the first substrate. The first light emitting element is coupled to a surface of the first substrate that faces the second substrate. The first light emitting element is configured to emit light through the second substrate. The second light emitting element is coupled to a surface of the second substrate that faces the first substrate. The second light emitting element is configured to emit light through the first substrate.
Another embodiment relates to a light source for a vehicle including a first substrate, a second substrate, a first LED, and a second LED. The second substrate is spaced apart from the first substrate. The first LED is coupled to a surface of the first substrate that faces the second substrate. The first LED is configured to emit light through the second substrate. The second LED is coupled to a surface of the second substrate that faces the first substrate. The second LED is configured to emit light through the first substrate.
Another embodiment relates to a light source for a vehicle including a first substrate, a second substrate, a first light emitting element, and a second light emitting element. The first substrate includes a substantially transparent portion. The second substrate is spaced apart from the first substrate and includes a substantially transparent portion. The first light emitting element is coupled to a surface of the first substrate that faces the second substrate. The first light emitting element is configured to emit light through the substantially transparent portion of the second substrate. The second light emitting element is coupled to a surface of the second substrate that faces the first substrate. The second light emitting element is configured to emit light through the substantially transparent portion of the first substrate.
Referring generally to the FIGURES, disclosed herein are various exemplary embodiments of a non-incandescent light source for a vehicle that is configured as a direct replacement for a tungsten-halogen light source (e.g., H11, HB2, HB3, H7, H4, etc.) or other incandescent light source on a vehicle (e.g., 3156/7, T-20 and other signal and marking lamps based on plastic and glass wedge-type bases that are listed in SAE J573 for miniature lamps). The light source of the present application can, advantageously, produce a light emission pattern (e.g., visible light radiation pattern, etc.) that is substantially the same as, or similar to, the emission pattern of a traditional tungsten-halogen bulb or incandescent bulb (e.g., a 4π radiation pattern, etc.), while providing for improved brightness, useful life, reliability, and customization, as compared to traditional tungsten-halogen bulbs and aftermarket LED light sources. The disclosed light source can be used for any automotive lighting function, such as high beam (upper beam), low beam (lower beam), front fog lamp, signal functions (e.g., front turn signal, rear turn signal, back-up (reversing lamp), rear fog, stop, tail, high mount stop lamp, etc.), or other automotive lighting applications.
Generally speaking, traditional automotive exterior lighting has included halogen sealed beams and other incandescent light sources. More recently, the automotive industry has started transitioning to LED and other non-incandescent light sources for roadway illumination and light signaling, such as laser diode, laser activated remote phosphor, organic LED (OLED), and other non-incandescent light sources.
Currently, however, there is no standard non-incandescent light source on the market that can replace a traditional tungsten-halogen or incandescent light source on vehicles that originally came equipped with these light sources. There are numerous aftermarket products that claim to be retrofit LED light sources. Most of these aftermarket products, however, do not accurately replicate the beam pattern produced by the tungsten filament they claim to replace, which is often due to differences in the light emitting area of the light source itself. Thus, when these aftermarket LED light sources are used in, for example, headlight assemblies including reflectors that are specifically designed for tungsten-halogen light sources, the light produced by these LED light sources is scattered and can cause nuisance glare to oncoming drivers.
For example, to increase the amount of light output or to create the appearance of increased brightness, many aftermarket LED light sources include additional light emitting elements (e.g., LEDs, etc.) located in the proximity of the designed “light center” or focal point of the light source. Referring to
In addition, some aftermarket LED light sources have light emission windows that are significantly different from the light emission windows of traditional tungsten-halogen bulbs, such that the resulting beam patterns of the LED light sources vary from the beam patterns of tungsten-halogen bulbs, which can result in increased nuisance glare and poor illumination for a driver. For example,
Similarly,
Additionally, because the LEDs 11d, 11e are each located on opposite sides of a single substrate/circuit board, the optical emission surface of the light sources 10d, 10e is separated by a distance that is much larger than the width of the tungsten-halogen filament, which functions as the optical emission surface of the traditional tungsten-halogen coil and is limited to the shape or diameter of the coil itself (e.g., approximately 1 mm in diameter, etc.). This separation in the optical emission surface can create gaps in the emission pattern resulting in “dim” areas in the beam pattern of the LED light source, which is undesirable. Furthermore, the waste heat produced by each LED 11d, 11e is concentrated at the base of the LED die on each side of the same substrate/circuit board, which can cause an increase in the thermal load of each LED and can reduce the luminous efficacy of each LED.
Disclosed herein is a vehicle light source that can substantially replicate the beam pattern of a traditional tungsten halogen bulb, while providing for improved brightness, useful life, reliability, and customization, as compared to traditional tungsten-halogen bulbs and aftermarket LED light sources. According to an exemplary embodiment, the light source includes two substantially parallel substrates and at least one LED coupled to each of the substrates, indirectly across from each other. The substrates each include a substantially transparent portion to allow for light emitted from the LEDs to pass through an opposite substrate along the primary emission axis of each LED. In this manner, the disclosed light source can provide an improved beam pattern by avoiding displacement of the light center of the LEDs, as compared to typical aftermarket LED light sources. Furthermore, by placing the LEDs on opposite substrates, the thermal resistance of each LED can be reduced and the luminous efficacy improved, because the waste heat produced by the LEDs at the base of each LED die is distributed to separate substrates that are spaced apart from each other, instead of a single substrate.
Additionally, the disclosed LED light source includes a rotary assembly that allows for optical adjustment of the resulting beam pattern from the LEDs, to thereby achieve an optimum beam pattern for a particular lighting application, unlike conventional aftermarket LED light sources, which typically have fixed beam patterns.
Referring to
As shown in
According to an exemplary embodiment, the substrates 25 are each made from a ceramic material, such as aluminum oxide. According to other exemplary embodiments, the ceramic material includes zirconia (ZrO2), magnesia (MgO), or other substantially transparent ceramic materials (e.g., sapphire, garnet, YAG ceramic, or carbon (diamond)). For example, according to an exemplary embodiment, the substrates are made from Al2O3 (aluminum oxide, alumina or corundum) that is sintered in such a way, so as to control the grain size and reduce porosity to produce a substantially transparent substrate. The process to produce substantially transparent ceramic materials can include various sintering techniques, such as a spark plasma sintering (SPS), vacuum sintering, high pressure (HP), hot isostatic pressure (HIP), and microwave sintering on alumina, zirconia, and other more complex ceramics. The Applicant discovered that these materials can, advantageously, allow for improved thermal conductivity of the substrate and allow for a reduction in substrate thickness for vehicle lighting applications. According to an exemplary embodiment, the substrates 25 each have a thickness of approximately 0.5 mm (e.g., ±0.25 mm). Furthermore, the substrates 25 each have a generally planar shape, and include a substantially transparent portion (e.g., between approximately 60% and approximately 98% straight line transparency (±2.0%)). In this way, the substrates 25 define light emission windows that mimic the light emission window of a tungsten-halogen light source and can allow a substantial amount of light emitted from the light emitting elements 32, 33 to pass therethrough, the details of which are discussed in the paragraphs that follow.
As shown in
According to the exemplary embodiment shown in
Referring to
Referring to
For example, referring to
According to an exemplary embodiment, the rotary assembly 22 includes an outer ring member 27 rotatably coupled to an inner ring member 28. The inner ring member 28 is coupled to the substrate base 24 and the substrates 25. The inner ring member 28 can include an opening to allow for wires or other electrical connectors to pass through between the substrates 25 and the primary base 21. The inner ring member 28 includes an undulating portion 29 that defines a plurality of detents disposed along an annular periphery of the inner ring 28. According to an exemplary embodiment, the plurality of detents are spaced apart from each other by between approximately 18 degrees and approximately 20 degrees, although other angular spacing is contemplated, according to other exemplary embodiments. According to the exemplary embodiment shown, the undulating portion 29 extends 180 degrees (i.e., semi-annular). According to other exemplary embodiments, the undulating portion 29 can extend greater than, or less than, 180 degrees about the substrate base 24 and the substrates 25. A ball member 30 and spring 31 are disposed between the outer ring member 27 and the inner ring member 28. The ball member 30 is biased by the spring 31 against the undulating portion 29 of the inner ring member. The inner ring member 28 can be selectively rotated by an installer relative to the outer ring member 27 (or vice versa) in a direction indicated generally by arrow “F,” such that the ball member 30 can selectively engage with, and disengage from, the plurality of detents, as indicated generally by arrow “G,” to set a rotational position of the substrate base 24 and the substrates 25 relative to the primary base 21. In this way, the beam pattern of the light source 20 can be selectively changed to fit a particular application.
Still referring to
Referring to
The disclosed vehicle light source can substantially replicate the beam pattern of a traditional tungsten-halogen bulb, while providing for improved brightness, useful life, reliability, and customization, as compared to traditional tungsten halogen bulbs and aftermarket LED light sources. The disclosed light source includes two substantially parallel substrates and at least one LED coupled to each of the substrates, indirectly across from each other. The substrates include substantially transparent portions that allow for light emitted from the LEDs to pass through an opposite substrate along the primary emission axis of each LED. In this manner, the disclosed light source can provide an improved beam pattern by avoiding displacement of the light center of the LEDs, as compared to typical aftermarket LED light sources. Furthermore, by placing the LEDs on opposite substrates, the thermal resistance of each LED can be reduced and the luminous efficacy improved, because the waste heat produced by the LEDs at the base of each LED die is distributed to separate substrates that are spaced apart from each other, instead of a single substrate. Additionally, the disclosed LED light source includes a rotary assembly that allows for optical adjustment of the resulting beam pattern from the LEDs, to thereby achieve an optimum beam pattern for a particular lighting application, unlike conventional aftermarket LED light sources, which typically have fixed beam patterns.
As utilized herein, the terms “approximately,” “about,” “substantially,” “essentially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.
It should be noted that the term “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.
References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
It is important to note that the construction and arrangement of the vehicle light source as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, manufacturing processes, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.
This application claims the benefit of and priority to U.S. Provisional Application No. 62/588,829, filed Nov. 20, 2017, the entire disclosure of which is hereby incorporated by reference herein.
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