TWI870855B - Vehicle headlight - Google Patents

Abstract

A traffic lamp, comprising: at least one LED light source; a projection module installed in front of the LED light source; and an outer lens located in front of the projection module; wherein the projection module has at least one projection, and the projection module is integrally made of silicone. The invention has the advantages of easy volume reduction, high weather resistance, simplified production process and reduced manufacturing cost.

Description

General traffic lights

The present invention relates to lighting technology, in particular to a headlamp for a vehicle.

The development of vehicle headlights has gone through the development process of incandescent lamps, halogen lamps, xenon headlights, LEDs and laser lamps. Among them, LED is currently the most commonly used light source for traffic lights. LED is a new type of headlight light source that has appeared in recent years. Compared with incandescent lamps, halogen lamps and xenon headlights, LED headlights have the advantages of long irradiation distance, low power consumption and high brightness. In order to make LED headlights suitable for the lighting needs of automobile headlights, motorcycle headlights and electric vehicle headlights, and to meet the corresponding regulatory requirements, it is necessary to carry out adaptive design of LED headlights for different types of vehicles.

The main purpose of this invention is to simplify the adaptive design of LED headlights so that they can meet the needs of various traffic lighting and meet the corresponding regulatory requirements.

In order to achieve the above and other purposes, the present invention provides a general traffic lamp, which includes: an LED light source; a free-form surface projection module installed in front of the LED light source; and an outer lens located in front of the free-form surface projection module; wherein the free-form surface projection module has at least one projector, and the free-form surface projection module is formed by integrally forming silicone. The projector includes a focusing portion, a reflective curved surface, and a light emitting surface. A light beam emitted by the LED light source is refracted and totally reflected by the free-form surface projection module and then projected toward the outer lens in parallel along an optical axis. The curved surface design of the outer lens is used to form the light beam into a preset light shape.

The headlamp structure of the present invention is mainly composed of a free-form surface projection module and an outer lens. The free-form surface projection module projects all light parallel to the optical axis to the distance, and uses the curved surface design of the outer lens to meet the light shape required by regulations, so as to meet the requirements of the corresponding regulations and achieve the effect of illuminating the road and preventing glare.

The free-form surface projection module of the present invention is designed and optimized entirely with free-form surfaces. The system is divided into two parts, one is the total reflection part and the other is the refraction part. The universal traffic lamp of the present invention can distribute and control light to meet the regulatory requirements of different vehicles. By controlling the light, the overall volume can be made smaller and the focusing efficiency will be higher.

The present invention uses a free-form surface design to shape the light. Compared with ordinary lenses, the number of lenses used and the thickness of the lenses are reduced while maintaining the same shaping effect. By using multiple LED diodes as light sources, the brightness of general traffic lamps is greatly increased. By replacing different LED particles and adjusting their power, different vehicle lighting needs can be met.

According to the technical solution of the present invention, the universal traffic lamp can be made more universal and smaller in size, realizing the universality of different vehicle lighting, and has the characteristics of long lighting distance, high lighting intensity and low energy consumption.

The general traffic lamp of the present invention can be installed with a baffle in front of the free-form surface projection module. The baffle is not limited to a single baffle, and a combination of baffles suitable for different traffic vehicles can be used. For example, a car has a 45-degree or 15-degree baffle; when used for a motorcycle, it will be replaced with a flat baffle without an angle; a flat baffle will also be used for electric vehicle lighting; a flat baffle can also be used for bicycle lighting. When replacing the baffle, the power of the chip and the corresponding number of LED particles will be adjusted accordingly, but there is no need to redesign the free-form surface projection module. By replacing the baffle and LED light source particles, different vehicle lighting needs can be met, such as the lighting needs of electric vehicles, motorcycles and cars. When designing the free-form projection module, the lighting changes caused by different numbers of LED light source particles and power have been taken into consideration. This change can be used to meet different vehicle lighting requirements.

10: External lens

20: Shell

30: Baffle

31: Guard plate carrier

40: Free-form surface projection module

401: Projector

41: Spotlight Department

42: Reflective surface

43: Light emitting surface

50: Circuit board

60: Radiator

70:LED light source

Figure 1 is a three-dimensional schematic diagram of an embodiment of the present invention.

Figure 2 is an exploded view of Figure 1 of the present invention.

Figure 3 is an exploded view of Figure 2 of the present invention.

Figure 4 is a two-dimensional structural diagram of an implementation of the present invention.

Figure 5 is a schematic diagram of the optical path of the projector in Figure 4 of the present invention.

Figure 6 is a three-dimensional diagram of a free-form surface projection module according to an embodiment of the present invention.

Please refer to Figures 1 to 6, which show an embodiment of a general traffic lamp provided by the present invention, including: a heat sink 60, a plurality of LED light sources 70, a free-form surface projection module 40, a baffle 30, and an outer lens 10. The LED light source 70 is mounted on a circuit board 50, which is mounted on the heat sink 60, and a housing 20 is mounted on the heat sink 60. The outer lens 10, the baffle 30, and the free-form surface projection module 40 are sequentially located in the housing 20, so that the outer lens 10 is at a position farthest from the LED light source 70. In addition, the baffle 30 is mounted on a baffle support frame 31, and the baffle support frame 31 is mounted on the heat sink 60.

The free-form surface projection module 40 is made of silicone material and has a plurality of projectors 401 arranged side by side. Each projector 401 has a focusing portion 41, a reflective curved surface 42 and a light emitting surface 43. The LED light source 70 is aligned with the focusing portion 41. The LED light source 70 emits a light beam which is refracted by the focusing portion 41 of the free-form surface projection module 40 or totally reflected by the reflective curved surface 42. The light beam is then directed parallel to the baffle 30 along an optical axis until it reaches the outer lens 10. The curved surface design of the outer lens 10 is used to form the light beam into a preset light shape.

The light focusing portion 41 is a circular concave portion and faces the LED light source 70 as the light input end. The light focusing portion 41 is divided into different areas in the circumferential direction and is designed separately in each area to meet the lighting needs of different traffic vehicles at the same time, or to meet the needs of special vehicles for special lighting effects at different circumferential positions of the free-form surface projection module 40.

The projector 401 of the free-form surface projection module 40 is a collimator, which enables the LED light source 70 to be focused by the collimator and then emitted in parallel.

The free-form surface projection module 40 is made of silicone and is integrally formed. Compared with free-form surface projection modules made of glass or PC (polycarbonate plastic), it will not yellow or change during use. In addition, silicone has high weather resistance and high tolerance to high or low temperatures, and is not easily affected by the environment and cracked. Compared with the free-form surface projection module 40 made of glass, its structural features need to be polished by machines, the manufacturing cost is higher, and the volume is not easy to shrink, resulting in an increase in the volume of the entire headlight. Therefore, the present invention is a free-form surface projection module 40 integrally formed with silicone, which is not only easy to shrink its overall volume and has high weather resistance, but also helps to simplify the production process and reduce manufacturing costs.

In this embodiment, the outer surface of the outer lens 10 is an aspherical surface, and its surface equation is:

Where c is the curvature, k is the cone coefficient, C1, C2, C3...C20 are the aspheric coefficients, x is the rotational symmetry axis of the aspheric surface, and z represents the incident height of the incident light on the aspheric surface.

The outer lens 10 is also made of silicone material and is a lens with multiple focal points. Silicone material has high weather resistance and high tolerance to high or low temperatures. It is not easily affected by the environment and cracked, nor will it yellow or deteriorate.

As shown in Figures 4 and 5, the light collecting part 41 of the projector 401 of the free-form surface projection module 40 is divided into a plurality of refraction blocks facing the receiving surface of the incident light at a small angle, so that these refraction blocks have at least two focal length specifications, and the orthographic projections of these refraction blocks along the optical axis are a plurality of concentric sectors, and the sum of the central angles of all sectors is 360 degrees, and two adjacent refraction blocks form a step structure at the junction. The aforementioned sector-shaped zoning design can make different areas of the free-form surface projection module 40 in the circumferential direction have different light collection efficiency, light utilization rate and lighting effect, and at the same time, the structure is relatively simple, and the light distribution can be quickly adjusted to meet the lighting needs of different vehicles.

The reflective curved surface 42 of the projector 401 is divided into multiple total reflection blocks, which are all segments of a rotational curved surface centered on the optical axis, but these total reflection blocks have at least two different curved surface designs. The orthographic projections of all total reflection blocks along the optical axis are multiple concentric sectors, and the sum of the central angles corresponding to all sectors is 360 degrees. Two adjacent total reflection blocks form a step structure at the junction.

In this embodiment, the total reflection block and the refraction block correspond to each other radially, and the central angles of the corresponding total reflection blocks and refraction blocks coincide.

After adjusting the light distribution through the design of the free-form surface projection module 40, the light distribution is projected through the external lens 10. After corresponding calculations, different regulatory requirements and illumination requirements can be met.

Different transportation tools have different traffic lighting requirements and regulations. To realize a universal traffic lighting design, the main method is to control the free-form surface projection module 40, the change of the baffle 30 and the number of particles of the LED light source 70.

In order to overcome the defect that traditional general traffic lamps are difficult to achieve high efficiency, the embodiment of the present invention disperses the surface light source into several LED point light sources and corresponds to different projectors 401. The focusing part 41 of each projector 401 can have different profiles. The different profiles of the focusing part 41 are multiplied by weight coefficients respectively, and these weighted profiles are superimposed. Then, the superimposed profile is optimized. The optimized variables are these weight coefficients. The particle swarm optimization algorithm is used to find the best weight ratio to improve the efficiency of the system. Simulation verification shows that the efficiency can be improved by 20% to 30%. The working principle of the optimized focusing part 41 is total reflection. In the process of transmitting light, part of the light is transmitted by light using the principle of total reflection.

The light-emitting surface of the projector 401 is a free-form surface, which is used for light shape distribution. The free-form surface data is designed based on the road illumination required by large passenger transportation and the intensity value of the test point at 25m. The light-emitting surface is based on the intensity required by the test point, and then the surface shape of the free-form surface is designed to control the change of the surface shape, so as to achieve the intensity value that meets different demand points. According to the arbitrary change of the free-form surface, different intensity requirements can be met, and the intensity value can be increased, decreased, and the width requirement design can be realized, so as to meet the miniaturization and high efficiency in the actual lighting process, and at the same time meet the verification of regulations.

When designing, it is necessary to consider the commonalities and similarities between different regulations, and then meet different needs by adjusting the light distribution. For example, when meeting the lighting needs of automobile roads, the intensity values of various regulatory points must be considered. If the lighting needs of motorcycles are to be met, the corresponding baffle 30 and the number of particles of the LED light source need to be replaced to meet the lighting needs of motorcycles. When designing the free-form surface projection module 40, the lighting changes caused by the number of particles and power of different LED light sources have been considered, and this change can be used to meet different lighting needs.

The above content is only the best implementation method of the present invention. For ordinary technicians in this field, according to the idea of the present invention, there will be changes in the specific implementation method and application scope. The content of this manual should not be understood as a limitation of the present invention.

10: External lens

20: Shell

30: Baffle

31: Guard plate carrier

40: Free-form surface projection module

50: Circuit board

60: Radiator

Claims (8)

A general traffic lamp comprises: at least one LED light source; a free-form surface projection module installed in front of the LED light source; and an outer lens located in front of the free-form surface projection module; wherein the free-form surface projection module has at least one projector, the light-emitting surface of the projector is a free-form surface, and the free-form surface projection module is formed by one-piece molding of silicone; the outer lens is formed by one-piece molding of silicone material; wherein the free-form surface projection module projects all light parallel to the optical axis toward a distant object. The invention relates to a method for producing a light shape that meets regulatory requirements by using the curved surface of the outer lens; wherein at least one LED light source is mounted on a circuit board, the circuit board is mounted on a heat sink, a housing is mounted on the heat sink, and the outer lens and the free-form surface projection module are located in the housing; wherein a baffle is mounted in front of the free-form surface projection module, the baffle is mounted on a baffle support, and the baffle support is mounted on the heat sink; wherein an outer surface of the outer lens is an aspherical surface, and its surface shape equation is:

Wherein c is the curvature, k is the cone coefficient, C1, C2, C3...C20 are the aspheric coefficients, wherein x is the rotational symmetry axis of the aspheric surface, and z represents the incident height of the incident light on the aspheric surface; wherein each of the projectors has a focusing portion, a reflecting curved surface and a light-emitting surface, and the LED light source is aligned with the focusing portion; wherein the receiving surface of the focusing portion of the projector facing the small-angle incident light is divided into a plurality of refractive blocks; wherein the refractive blocks have at least two focal length specifications; wherein the orthographic projections of the refractive blocks along the optical axis direction are a plurality of concentric sectors, and the sum of the central angles of all the sectors is 360 degrees, with the plane passing through the designed optical axis as the interface, and two adjacent refractive blocks form a stepped structure at the interface. The general traffic light as described in claim 1, wherein the focusing portion is a circular concave portion. The general traffic light as described in claim 1, wherein the reflective curved surface is divided into a plurality of total reflection blocks, and two adjacent total reflection blocks form a step structure at the junction. The general traffic lamp as described in claim 3, wherein the total reflection blocks have at least two different curved surface designs. The general traffic lamp as described in claim 1, wherein the focusing portion is a circular concave portion, the focusing portion is divided into a plurality of refraction blocks in the circumferential direction, the reflection curved surface is divided into a plurality of total reflection blocks, and the total reflection blocks correspond to the refraction blocks one by one in the radial direction with an optical axis as the center. The general traffic light as described in claim 1, wherein the number of the projectors is plural and the projectors are arranged side by side. The general traffic lighting fixture as described in claim 1, wherein at least one projector is a collimator. The general traffic light as described in claim 1, wherein the outer lens is a multifocal lens having multiple focal points.