Solid state steerable light

• US 10,427,591 B2
• Filed: 10/16/2015
• Issued: 10/01/2019
• Est. Priority Date: 01/03/2012
• Status: Active Grant

• Current Assignee: J.W. Speaker, Corporation
• Original Assignee: J.W. Speaker, Corporation
• Inventors: Kay, Bradley William, McWithey, Kevin Jay
• Primary Examiner(s): Owens, Douglas W
• Assistant Examiner(s): Yang, Amy X
• Application Number:
  US14/885,052
• Publication Number:
  US 20160096468A1
• Time in Patent Office: 1,446 Days
• CPC Class Codes: B60Q 1/12 due to steering position
• CPC Class Codes: B60Q 1/1423 Automatic dimming circuits, i.e. switching between high beam and low beam due to change of ambient light or light level in road traffic
• CPC Class Codes: B60Q 1/143 combined with another condition, e.g. using vehicle recognition from camera images or activation of wipers
• CPC Class Codes: B60Q 2300/056 Special anti-blinding beams, e.g. a standard beam is chopped or moved in order not to blind
• CPC Class Codes: B60Q 2300/12 Steering parameters
• CPC Class Codes: B60Q 2300/42 oncoming vehicle
• CPC Class Codes: F21S 41/143 the main emission direction of the LED being parallel to the optical axis of the illuminating device
• CPC Class Codes: F21S 41/151 arranged in one or more lines
• CPC Class Codes: F21S 41/255 Lenses with a front view of circular or truncated circular outline
• CPC Class Codes: F21S 41/285 Refractors, transparent cover plates, light guides or filters not provided in groups F21S41/24 - F21S41/2805
• CPC Class Codes: F21S 41/663 by switching light sources by switching incandescent light sources F21S41/162
• CPC Class Codes: F21W 2102/19 for curves
• CPC Class Codes: F21Y 2103/10 comprising a linear array of point-like light-generating elements
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: H05B 45/10 Controlling the intensity of the light
• CPC Class Codes: H05B 45/325 Pulse-width modulation [PWM]
• CPC Class Codes: H05B 45/37 Converter circuits

Abstract

A light assembly for generating a light pattern comprising LEDs; a first lens positioned in front of the LEDs to direct light from each LED into an illumination field, the illumination fields of energized LEDs create an illumination pattern and a first edge illumination field and a second edge illumination field; a processor controlling the LED duty cycles to move the illumination pattern in a first direction to the side of the first edge illumination field by (i) increasing an LED duty cycle associated with the first edge illumination field while decreasing an LED duty cycle associated with the second edge illumination field; and (ii) repeating step (i) with the illumination field adjacent the first edge illumination field in the first direction as the first edge illumination field and with the illumination field adjacent the second edge illumination field in the first direction as the second edge illumination field.

Claims

1. A light assembly for generating a light pattern, the assembly comprising:

a a first bank of LEDs and a second bank of LEDs mounted in a line, each LED in the first bank and the second bank having a duty cycle;

a first lens positioned in front of the first bank of LEDs to direct light from each LED into an illumination field associated with the LED;

a second lens positioned in front of the second bank of LEDs to direct light from each LED into an illumination field associated with the LED, wherein the illumination fields of energized LEDs in the first bank and the second bank together create an illumination pattern, wherein a separate illumination field associated with the first bank LEDs overlaps each two adjacent illumination fields associated with the second bank while a separate illumination field associated with the second bank LEDs overlaps each two adjacent illumination fields associated with the first bank, and wherein a first edge illumination field is at one end of the illumination pattern and a second edge illumination field is at another end of the illumination pattern opposite the one end; and

a processor controlling the LED duty cycles to move the illumination pattern projected by the first lens and the second lens in a first direction to the side of the first edge illumination field opposite the second edge illumination field by;

(i) increasing a duty cycle of an LED associated with the first edge illumination field while simultaneously decreasing a duty cycle of an LED associated with the second edge illumination field; and

(ii) repeating step (i) with the illumination field adjacent the first edge illumination field in the first direction as the first edge illumination field and with the illumination field adjacent the second edge illumination field in the first direction as the second edge illumination field.

2. The assembly of claim 1, wherein the duty cycle of the LED associated with the first edge illumination field is increased while the duty cycle of the LED associated with the second edge illumination field is decreased until the duty cycles of the LEDs associated with the first and second edge illumination fields are maximum and minimum duty cycles, respectively.

3. The assembly of claim 2, wherein the maximum and minimum duty cycles are 100% and 0% duty cycles.

4. The assembly of claim 1, wherein at least one LED is driven with 100% duty cycle at any time.

5. The assembly of claim 1, wherein only three LEDs in the plurality of LEDs are driven at a non-zero duty cycle at any time.

6. The assembly of claim 1, wherein the processor is also for controlling the LED duty cycles to move the illumination pattern projected by the lens in a second direction to the side of the second edge illumination field opposite the first edge illumination field by:

(iii) increasing the duty cycle of an LED associated with the second edge illumination field while decreasing the duty cycle of an LED associated with the first edge illumination field until the duty cycles of the LEDs associated with the second and first edge illumination fields are maximum and minimum duty cycles, respectively; and

(iv) repeating step (iii) with the illumination field adjacent the second edge illumination field in the second direction as the second edge illumination field and with the illumination field adjacent the first edge illumination field in the second direction as the first edge illumination field.

7. The assembly of claim 1, wherein the duty cycle of the LED associated with the second edge illumination field is increased while the duty cycle of the LED associated with the first edge illumination field is decreased until the duty cycles of the LEDs associated with the second and first edge illumination fields are maximum and minimum duty cycles, respectively.

8. The assembly of claim 1, wherein no more than two LEDs in the first and second banks of LEDs are driven at partial duty cycles at one time.

9. The assembly of claim 1, wherein the processor receives a control signal to turn LEDs in the first and second banks of LEDs on and off to adjust the angles of light projected by the first and second lenses.

10. The assembly of claim 1, wherein the processor controls the LEDs in the first bank of LEDs differently than the processor controls the LEDs in the second bank of LEDs.

11. The assembly of claim 1, wherein the plurality of LEDs comprises at least three LEDs and wherein no more than three LEDs in the first and second bank of LEDs are on at one time.

12. The assembly of claim 1, wherein at least one LED in at least one of the first and second banks of LEDs is driven at a maximum intensity at all times.

13. The assembly of claim 1, wherein the processor receives a control signal to adjust intensity of the LEDs in the first and second bank of LEDs to adjust the direction of a combined light pattern emanating from the first and second lenses.

14. The assembly of claim 13, wherein when at least one LED in one of the first and second banks of LEDs is driven with a high intensity to generate a relatively high intensity area in the combined light pattern, LEDs in the other of the first and second banks of LEDs that illuminate areas in the combined light pattern on either side of the high intensity area are driven with a lower intensity that is lower than the high intensity to generate lower intensity areas adjacent the high intensity areas in the combined light pattern.

15. The assembly of claim 13, wherein the combined light pattern can be adjusted within a range of positions from a first position wherein a single LED at a first end of each of the first and second light modules is driven with a high intensity and at least a subset of the other LEDs in the light modules are off and a last position wherein a single LED at a second end of each of the first and second light modules is driven with a high intensity and at least a subset of the other LEDs in the light modules are off.

16. The assembly of claim 13, wherein, when the combined light pattern is at a position between the first and last positions, only a subset of the LEDs in the first and second banks of LEDs is on and at least a subset of the LEDs that are on are driven with a duty cycle that is less than a maximum duty cycle.

17. The assembly of claim 1, wherein no more than three LEDs in the first and second banks of LEDs are driven at any time.

18. The assembly of claim 1, wherein only one LED in the first and second banks of LEDs is driven at a maximum duty cycle and only two LEDs in the first and second banks of LEDs are driven at less than the maximum duty cycle.

19. The assembly of claim 18, wherein the two LEDs that are driven at less than the maximum duty cycle generate illumination fields that at least partially overlap the illumination fields generated by the LED that is driven at the maximum duty cycle.

20. The assembly of claim 1, wherein the assembly is a first assembly and generates a first combined light pattern and where the first assembly is for use with a second assembly to form a pair of headlights on a vehicle wherein the second assembly generates a second combined light pattern that mirrors the first combined light pattern, the first and second assemblies arranged so that the first and second combined light patterns are substantially aligned and combine to generate a headlight pattern.

21. The assembly of claim 1, wherein the LED lines are substantially horizontal and wherein the first and second banks of LEDs form a headlight for a vehicle.

22. The assembly of claim 1, wherein the LED lines are substantially vertical and wherein the first and second banks of LEDs form a light for use on a lift truck.

23. The assembly of claim 1, wherein each of the first and second lines of LEDs includes first through fifth LEDs and wherein the processor controls the intensities of each LED.

24. The assembly of claim 1, wherein the processor controls intensity of the LEDs via a pulse width modulation process.