U.S. patent application number 15/414229 was filed with the patent office on 2017-05-11 for headlight assembly with multiple high aspect ratio lenses.
The applicant listed for this patent is FORD GLOBAL TECHNOLOGIES, LLC. Invention is credited to Sleiman N. ABDELNOUR, David A. BROWN, Ketan K. DESAI, Stephen Kenneth HELWIG, Li YAN.
Application Number | 20170130927 15/414229 |
Document ID | / |
Family ID | 53759316 |
Filed Date | 2017-05-11 |
United States Patent
Application |
20170130927 |
Kind Code |
A1 |
DESAI; Ketan K. ; et
al. |
May 11, 2017 |
HEADLIGHT ASSEMBLY WITH MULTIPLE HIGH ASPECT RATIO LENSES
Abstract
A headlight assembly including a plurality of low-beam modules
and a plurality of high-beam modules are enclosed in a housing. The
low-beam modules include a top reflector disposed above a low-beam
LED light source that projects a height limited first beam of light
through the low-beam lens. The high-beam modules include a bottom
reflector disposed below a high-beam LED light source that projects
a second beam of light through a high-beam lens above the first
beam of light. Each module has an aspect ratio of 2:1 with the
height of the lens being twice the width of the lens.
Inventors: |
DESAI; Ketan K.; (Farmington
Hills, MI) ; BROWN; David A.; (West Bloomfield,
MI) ; YAN; Li; (Troy, MI) ; HELWIG; Stephen
Kenneth; (Farmington Hills, MI) ; ABDELNOUR; Sleiman
N.; (Macomb, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORD GLOBAL TECHNOLOGIES, LLC |
Dearborn |
MI |
US |
|
|
Family ID: |
53759316 |
Appl. No.: |
15/414229 |
Filed: |
January 24, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14283614 |
May 21, 2014 |
9587794 |
|
|
15414229 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21S 41/285 20180101;
F21S 45/47 20180101; B60Q 1/0041 20130101; F21S 41/26 20180101;
F21S 41/657 20180101; B60Q 1/0683 20130101; F21S 41/36 20180101;
F21Y 2115/10 20160801; F21S 41/147 20180101; F21S 41/47 20180101;
F21S 41/32 20180101; F21S 41/675 20180101; F21S 41/19 20180101;
F21S 41/40 20180101; F21S 41/365 20180101 |
International
Class: |
F21S 8/10 20060101
F21S008/10; B60Q 1/00 20060101 B60Q001/00; B60Q 1/068 20060101
B60Q001/068 |
Claims
1. A headlight assembly comprising: a housing; a plurality of
low-beam modules attached to the housing including a top reflector
disposed above a low-beam LED light source projecting a height
limited first beam of light through a low-beam lens; and a
plurality of high-beam modules attached to the housing including a
bottom reflector disposed below a high-beam LED light source
projecting a second beam of light through a high-beam lens above
the first beam of light.
2. The headlight assembly of claim 1 wherein three low-beam modules
are assembled to the housing and two high-beam modules are
assembled to the housing at an inboard location relative to the
low-beam modules.
3. The headlight assembly of claim 1 wherein each low-beam module
further comprises: an LED support extending in a horizontal plane
and having an upper reflective surface that cooperates with the top
reflector to project the height limited first beam of light.
4. The headlight assembly of claim 1 wherein each high-beam module
further comprises: an LED support extending in a horizontal plane
and having a lower reflective surface that cooperates with the
bottom reflector to project the second beam of light.
5. The headlight assembly of claim 1 wherein the plurality of
low-beam modules and the plurality of high-beam modules are
assembled to the housing at an inboard location relative to the
low-beam modules, wherein the low-beam modules further comprise an
LED support extending in a horizontal plane and having an upper
reflective surface that cooperates with the top reflector to
project the height limited first beam of light; and the high-beam
modules further comprise an LED support extending in a horizontal
plane and having a lower reflective surface that cooperates with
the bottom reflector to project the second beam of light.
6. The headlight assembly of claim 5 wherein the upper reflective
surface of the plurality of low-beam modules relative to the top
reflector is at a different height than the height of the upper
reflective surface of an adjacent low-beam module, and wherein the
lower reflective surface of the plurality of high-beam modules
relative to the bottom reflector is at a different height than the
height of the lower reflective surface of an adjacent high-beam
module.
7. The headlight assembly of claim 1 wherein each low-beam modules
further comprises: an LED support extending in a horizontal plane
with a plurality of heat sink fins extending downwardly from the
horizontal plane and having an upper reflective surface that
cooperates with the top reflector to project the height limited
first beam of light.
8. The headlight assembly of claim 7 further comprising a light
blocker disposed between the upper reflective surface and the
low-beam lens that limits the height of the first beam of
light.
9. The headlight assembly of claim 1 wherein each high-beam module
further comprises: an LED support extending in a horizontal plane
with a plurality of heat sink fins extending upwardly from the
horizontal plane and having a lower reflective surface that
cooperates with the bottom reflector to project the second beam of
light.
10. The headlight assembly of claim 1 wherein the low-beam lens and
the high-beam lens have convex inner sides and convex outer sides
that are generated about a central axis extending in a projection
direction for each of the beams of light, and wherein two lateral
portions of each lens are truncated to form a vertically extending
lateral side surface of the lens.
11. A headlight module comprising: a reflective platform; a light
source attached to the platform; a partially parabolic reflector
facing the platform; and a lens having a convex inner side and
convex outer side that are each generated about a central axis
extending in a projection direction, and wherein two lateral
portions of the lens are both truncated to form a vertically
extending lateral side surface of the lens.
12. The headlight module of claim 11 wherein a height of the lens
is greater than a width of the lens.
13. The headlight module of claim 11 wherein a height of the lens
is more than two times a width of the lens.
14. The headlight module of claim 11 further comprising: a module
housing that is attached to the two lateral portions of the lens, a
lower end of the lens and an upper end of the lens, and wherein the
module housing encloses the reflective platform, the partially
parabolic reflector and the light source.
15. The headlight module of claim 14 further comprising: an
attachment mechanism that connects the reflective platform, the
partially parabolic reflector and the light source as a unit to the
housing within a range of vertical locations relative to the
central axis to adjust a light projection direction of the
module.
16. The headlight module of claim 11 wherein the reflector is
disposed above the platform and the light source to project a
height limited beam of light through the lens.
17. The headlight module of claim 11 wherein the reflector is
disposed below the platform and the light source to project a beam
of light in an upwardly inclined direction through the lens.
18. A headlight assembly comprising: a housing; a plurality of
low-beam modules attached to the housing including a top reflector
disposed above a low-beam LED light source projecting a height
limited first beam of light through a low-beam lens; and a
plurality of high-beam modules attached to the housing including a
bottom reflector disposed below a high-beam LED light source
projecting a second beam of light through a high-beam lens above
the first beam of light, wherein each of the lenses have a convex
inner side and convex outer side that are each generated about a
central axis extending in a projection direction, and wherein two
lateral portions of the lens are both truncated to form a
vertically extending lateral side surface of the lens.
19. The headlight assembly of claim 18 further comprising an
assembly housing wherein three low-beam modules are assembled to
the assembly housing and two high-beam modules are assembled to the
assembly housing at an inboard location relative to the low-beam
modules.
20. The headlight assembly of claim 18 further comprising: an
attachment mechanism that connects the top reflector and the
low-beam LED light source as a unit to the housing within a range
of vertical locations relative to the low-beam lens to adjust a
light projection direction of the low-beam modules, wherein the
attachment mechanism connects the bottom reflector and the
high-beam LED light source as a unit to the housing within a range
of vertical locations relative to the high-beam lens to adjust a
light projection direction of the high-beam modules.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. application Ser. No.
14/283,614 filed May 21, 2014, the disclosure of which is hereby
incorporated in its entirety by reference herein.
TECHNICAL FIELD
[0002] This disclosure relates to a headlight assembly that
includes a plurality of modular LED lights that provide low beam
and high beam illumination patterns.
BACKGROUND
[0003] Vehicles are provided with headlights that illuminate the
road in front of a vehicle. The beam pattern of vehicle headlights
is subject to safety standards such as Federal Motor Vehicle Safety
Standard (FMVSS) 108, ECE regulations and CCC regulations for
lighting. This safety standard regulates the height and spread of
low-beam headlights and high-beam headlights so that adequate
illumination is provided for a driver without blinding drivers of
on-coming vehicles.
[0004] Light Emitting Diode (LED) lights have been developed for
headlight applications because they offer excellent illumination,
energy savings, weight savings and longer service life. LED
headlights present challenges relating to providing an attractive
headlight assembly that also meets relevant safety standards.
[0005] This disclosure is directed to the above problems and other
problems as summarized below.
SUMMARY
[0006] A distinctive headlight assembly having a uniquely shaped
clear optical lens is provided for an LED light source. The LED
light source and reflectors are coupled to a plastic optical lens
that provide light to the lens that has a prescribed focal length.
The light is projected and distributed through the lens and to a
specific target area of the standards compliant legal beam pattern.
The aperture of the LED light source has an aspect ratio of 1:2
width to height to create a distinctive vertical appearance. The
aperture of the lens is curved in a horizontal plane and a vertical
plane to produce the desired spread pattern. The top and bottom
ends of the lens are narrower than the middle portion of the
lens.
[0007] According to one aspect of this disclosure, a headlight
assembly is provided that comprises a housing that encloses a
plurality of low-beam modules and a plurality of high-beam modules.
The low-beam modules include a top reflector disposed above a
low-beam LED light source that projects a height limited first beam
of light through a low-beam lens. The high-beam modules include a
bottom reflector disposed below a high-beam LED light source that
projects a second beam of light through a high-beam lens above the
first beam of light.
[0008] According to other aspects of this disclosure, three
low-beam modules may be assembled to the housing and two high-beam
modules may be assembled to the housing at an inboard location
relative to the low-beam modules.
[0009] The plurality of low-beam modules and the plurality of
high-beam modules may be assembled to the housing at an inboard
location relative to the low-beam modules. The low-beam modules may
further comprise an LED support extending in a horizontal plane
that has an upper reflective surface that cooperates with the top
reflector to project the height limited first beam of light. The
high-beam modules may further comprise an LED support extending in
a horizontal plane that has a lower reflective surface that
cooperates with the bottom reflector to project the second beam of
light.
[0010] The upper reflective surface of the plurality of low-beam
modules relative to the top reflector may be set at a different
height than the height of the upper reflective surface of an
adjacent low-beam module. The lower reflective surface of the
plurality of high-beam modules relative to the bottom reflector may
also be set at a different height than the height of the lower
reflective surface of an adjacent high-beam module.
[0011] Each low-beam modules may further comprise an LED support
extending in a horizontal plane with a plurality of heat sink fins
extending downwardly from the horizontal plane. The LED support may
have an upper reflective surface that cooperates with the top
reflector to project the height limited first beam of light. A
light blocker may be disposed between the upper reflective surface
and the low-beam lens that limits the height of the first beam of
light.
[0012] Each high-beam module may further comprise an LED support
extending in a horizontal plane with a plurality of heat sink fins
extending upwardly from the horizontal plane. The LED support may
also have a lower reflective surface that cooperates with the
bottom reflector to project the second beam of light.
[0013] The low-beam lens and the high-beam lens may have convex
inner sides and convex outer sides that are generated about a
central axis extending in a projection direction for each of the
beams of light. Two lateral portions of each lens are truncated to
form a vertically extending lateral side surface of the lens.
[0014] According to another aspect of this disclosure, a headlight
module is provided that comprises a reflective platform, a light
source attached to the platform, a partially parabolic reflector
facing the platform and a lens having a convex inner side and
convex outer side. The convex inner and outer sides are each
generated about a central axis extending in a projection direction.
Two lateral portions of the lens are both truncated to form a
vertically extending lateral side surface of the lens.
[0015] According to other aspects of this disclosure that relates
to the headlight module, a height of the lens is greater than a
width of the lens. The height of the lens may be more than two
times a width of the lens.
[0016] The headlight module may further comprise a module housing
that is attached to the two lateral portions of the lens, a lower
end of the lens and an upper end of the lens. The module housing
may enclose the reflective platform, the partially parabolic
reflector and the light source. An attachment mechanism may be
provided to connect the reflective platform, the partially
parabolic reflector and the light source as a unit to the housing
within a range of vertical locations relative to the central axis
to adjust a light projection direction of the module.
[0017] The reflector for a low-beam headlight is disposed above the
platform and the light source to project a height limited beam of
light through the lens. The reflector for a high-beam headlight is
disposed below the platform and the light source to project a beam
of light in an upwardly inclined direction through the lens.
[0018] According to another aspect of this disclosure, a headlight
assembly is provided that comprises a housing, a plurality of
low-beam modules and a plurality of high-beam modules. Each of the
low-beam modules include a top reflector disposed above a low-beam
LED light source that project a height limited first beam of light
through a low-beam lens. The high-beam modules include a bottom
reflector disposed below a high-beam LED light source that projects
a second beam of light through a high-beam lens above the first
beam of light. Each of the lenses have a convex inner side and
convex outer side that are each generated about a central axis
extending in a projection direction. Two lateral portions of the
lens are both truncated to form a vertically extending lateral side
surface of the lens.
[0019] The above aspects of this disclosure and other aspects will
be described in greater detail below with reference to the attached
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a fragmentary front perspective view of the right
headlight assembly made according to one embodiment of this
disclosure.
[0021] FIG. 2 is a fragmentary front elevation view of the right
headlight assembly shown in FIG. 1.
[0022] FIG. 3 is a diagrammatic vertical cross-section view of one
low beam module of the headlight shown in FIG. 1.
[0023] FIG. 4 is a diagrammatic front elevation view of three low
beam lenses and two high beam lenses with the lateral sides
truncated at vertically extending walls and the LED support
platforms at different heights relative to the lenses.
[0024] FIG. 5 is a front/side perspective view of one low beam
module of the headlight shown in FIG. 1.
[0025] FIG. 6 is a diagrammatic view of a low beam light projection
pattern created by the low beam lights only of the headlight
assembly.
[0026] FIG. 7 is a diagrammatic view of a high beam and low beam
light projection pattern created by the high beam and low beam
lights of the headlight assembly.
DETAILED DESCRIPTION
[0027] The illustrated embodiments are disclosed with reference to
the drawings. However, it is to be understood that the disclosed
embodiments are intended to be merely examples that may be embodied
in various and alternative forms. The figures are not necessarily
to scale and some features may be exaggerated or minimized to show
details of particular components. The specific structural and
functional details disclosed are not to be interpreted as limiting,
but as a representative basis for teaching one skilled in the art
how to practice the disclosed concepts.
[0028] Referring to FIG. 1, a headlight assembly 10 for a vehicle
12 is illustrated that is made in accordance with one embodiment of
this disclosure. The headlight assembly 10 includes a set of three
low-beam modules 14 and a set of two high-beam modules 16. The
low-beam modules are disposed outboard of the high-beam modules.
Line "A" indicates the modules 14 illuminated in the low-beam mode.
Line "B" indicates the modules 14 and 16 illuminated in the
high-beam mode. The high-beam modules are closest to the centerline
of the vehicle. The headlight assembly 10, shown in FIG. 1, is a
right side headlight assembly that is located on the right side of
the vehicle in the vehicle direction.
[0029] A static bending light module 18 is also included as part of
the headlight assembly 10 that is used to project a light in the
direction to which the vehicle is turning. The static bending
module 18 is disposed inboard of the high-beam module 16. The
low-beam modules 14 and high-beam modules 16 are enclosed within a
housing 20. The housing 20 is assembled as a unit to the vehicle 12
after being assembled offline as a sub-assembly. The low-beam
modules 14 and high-beam modules 16 each include a outer lens 22
through which light is projected and a bezel 24 is provided that
extends around the outer lens 22 to provide a finished
appearance.
[0030] Referring to FIG. 2, the headlight assembly 10 is shown with
the lenses and the housing removed to reveal the internal structure
of the low-beam modules 14 and high-beam modules 16. The low-beam
modules 14 include a top reflector 26 that is disposed above an LED
light source 28. The LED light source may include two LED lights
that are assembled to a single chip. A reflective platform 30 is
provided on which the LED light source 28 is assembled. A plurality
of lower heat sink fins 32 extend downwardly from the platform 30
to dissipate heat from the LED light source and may also be used to
dissipate heat from a LED power source (not shown).
[0031] The high-beam modules 16 include a bottom reflector 34 that
is assembled below the LED light source 36. The LED light source 36
includes three LED lights that are assembled to a single chip. The
chip is mounted on a reflective platform 38. A plurality of upper
heat sink fins 40 are provided above the reflective platform 38 to
dissipate heat, as previously described.
[0032] It should be noted that the level of the top reflector 26,
LED light source 28 and reflective platform 30 is higher on the
outermost low-beam module 14 and is lowest on the innermost
low-beam module 14. The platform and other parts of the center
module are between the level of the platforms on the adjacent
modules, as shown in FIG. 2. The two high-beam modules 16, shown in
FIG. 2, also have slightly different heights relative to each
other. The innermost high beam module has a bottom reflector 34,
LED light source 36 and reflective platform 38 that is mounted
slightly lower than the outer high-beam module 16. The height of
the platforms 30, 38 and the LED light sources 28, 36 and top
reflector 26 and bottom reflector 34 are adjusted vertically
relative to the outer lens 22 (shown in FIG. 1) to permit the light
beam to be adjusted vertically to comply with FMVSS 108. The
arrangement of the low-beam module 14 provides a downwardly
directed light beam that result in a light projection pattern that
will be described below with reference to FIG. 6. The high-beam
modules 16 have a bottom reflector 34 that is disposed below the
LED light source 36 and reflective platform 38 to create an
upwardly directed light beam that creates a pattern in conjunction
with the low-beam modules 14, as shown in FIG. 7.
[0033] Referring to FIG. 3, a low-beam module 14 is illustrated in
greater detail. The headlight assembly 10 is shown assembled to a
vehicle 12. The housing 20 is supported by the vehicle 12. The
bezel 24 extends between the housing 20 and the outer lens 22. The
outer lens 22 includes a front convex surface 42 and a rear convex
surface 44. The front and rear convex surfaces 42 and 44 are
focused in accordance with FMVSS 108 to project a beam of light
below the horizon line. The beam of light created by the LED light
source 28 directs light toward the top reflector 26. The light is
reflected from the top reflector 26 to the reflective platform 30.
The front convex surface 42 and rear convex surface 44 are
generated about a central axis X as circular lenses.
[0034] A wiring connector, or socket, 46 is shown attached to the
platform 30. The platform 30 is shown to be supporting the LED
light source 28 and also supporting the top reflector 26. An upper
light blocker 48 is provided between the LED light source 28 on the
reflective platform 30 and the outer lens 22. The light blocker 48
blocks light from being projected above a desired level as required
by FMVSS 108. A lower light blocker 50 blocks light from being
projected below a desired level.
[0035] The module shown in FIG. 3 is a low-beam module 14. However,
it should be understood that the structure of the high beam module
16 is essentially identical, but the bottom reflector 34 and LED
light source and reflective platform 38 would be inverted in a
high-beam module 16. Note, the height of the platform and the other
components is adjusted to direct the light beam in the desired
pattern.
[0036] Referring to FIG. 4, a headlight assembly 10 is shown
diagrammatically to illustrate the lenses for the low-beam modules
14 and high-beam modules 16. The lenses 22 are a circular lens form
52 that is truncated on the right and left side. An upper right
side 54 (in the vehicle direction) and a lower right side 56 define
the right side of each lens. An upper left side 58 and a lower left
side 60 define the left side of the outer lens 22. An upper
extension 62 and a lower extension 64 are provided to create the
desired high aspect ratio lens. The lenses are molded in a mold
that includes the circular lens form 52 and the right and left
sides of the outer lens 22 are molded with the upper extension and
lower extension 62 and 64. The aspect ratio of each lens is the
ratio of 2:1 with the lens being twice as tall as it is wide for
each of the low and high-beam modules 14 and 16.
[0037] Referring to FIG. 5, a low-beam module 14 is shown separated
from the headlight assembly 10 (shown in FIG. 1). The low-beam
module 14 includes a side bracket 66 that secures the lens to the
reflective platform 30 and top reflector 26. A height adjustment
fastener 68 is provided to locate the reflective platform 30 and
top reflector 26 relative to the outer lens 22. The height
adjustment fastener 68 is received in a height adjustment
receptacle 70 that may be provided on the reflective platform
30.
[0038] Referring to FIG. 6, a low-beam illumination pattern 72 is
shown. The low-beam illumination pattern 72 is height limited to
not project light above the horizon line that is represented by
zero on the Y axis. The spread of the low-beam illumination pattern
72 extends to provide a wide beamin both directions relative to the
centerline indicated by the zero on the X axis in FIG. 6.
[0039] Referring to FIG. 7, a low-beam illumination pattern 72 and
a high-beam illumination pattern 74 are shown together. The
low-beam illumination pattern 72 is below the horizon line, or
zero, and the high-beam illumination pattern 74 is provided above
the horizon line. An area of maximum illumination is provided above
the horizon line in the center of the combined illumination pattern
72, 74. The high-beam illumination pattern 74 extends approximately
20.degree. to each side of the centerline and has a maximum height
of approximately 5.degree. above the horizon line with intensity
less than 5,000 candela.
[0040] The embodiments described above are specific examples that
do not describe all possible forms of the disclosure. The features
of the illustrated embodiments may be combined to form further
embodiments of the disclosed concepts. The words used in the
specification are words of description rather than limitation. The
scope of the following claims is broader than the specifically
disclosed embodiments and also includes modifications of the
illustrated embodiments.
* * * * *