Low profile highly efficient vehicular LED modules and headlamps

• US 9,156,395 B2
• Filed: 01/08/2013
• Issued: 10/13/2015
• Est. Priority Date: 01/08/2013
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Kumar, Arun, Dassanayake, Mahendra Somasara, Ekladyous, Albert, Williams, Bruce Preston
• Primary Examiner(s): ULANDAY, MEGHAN K
• Application Number:
  US13/736,265
• Publication Number:
  US 20140192547A1
• Time in Patent Office: 1,008 Days
• Field of Search: 362/487, 362/509, 362/520, 362/522
• US Class Current: 1/1
• CPC Class Codes: B60Q 1/00 Arrangement of optical signalling or lighting devices, the mounting or supporting thereof or circuits therefor for lighting vehicle interior B60Q3/00
• CPC Class Codes: B60Q 1/04 the devices being headlights
• CPC Class Codes: F21S 41/24 Light guides
• CPC Class Codes: F21S 41/336 with discontinuity at the junction between adjacent areas
• CPC Class Codes: F21S 43/14 Light emitting diodes [LED]
• CPC Class Codes: F21S 43/20 characterised by refractors, transparent cover plates, light guides or filters
• CPC Class Codes: F21S 43/315 using total internal reflection
• CPC Class Codes: F21S 43/40 characterised by the combination of reflectors and refractors
• CPC Class Codes: F21V 5/04 of lens shape

Abstract

A vehicle lighting module is provided that includes a lens having a plurality of near-field lens elements, an input surface, and an exit surface. The lighting module also includes an LED light source that directs incident light through the input surface and out of the exit surface. The plurality of lens elements is configured to transmit from the exit surface a collimated light pattern containing at least 60% of the incident light. Further, a vehicle headlamp assembly is provided that includes a plurality of vehicle lighting modules, each module comprising a lens, and an LED light source that directs incident light through the lens. The assembly further includes a case for housing the lighting modules. The lens includes a plurality of lens elements configured to transmit at least 60% of the incident light in a collimated, vehicular light pattern.

Claims

1. A vehicle lighting module, comprising:

a lens having an input surface including a purality of near-field lens elements, and an exit surface, each element having a different focal length; and

an LED light source positioned to direct incident light through the input surface,

wherein the elements are configured to shape the light from the input surface into a collimated light pattern emanating from the exit surface containing at least 60% of the incident light.

2. The vehicle lighting module according to claim 1, wherein the light source and the exit surface of the lens collectively define a depth of approximately 50 millimeters or less.

3. The vehicle lighting module according to claim 1, wherein the light source and the exit surface of the lens collectively define a depth of approximately 25 millimeters or less.

4. The vehicle lighting module according to claim 1, wherein the exit surface of the lens is arranged in a substantially circular shape.

5. The vehicle lighting module according to claim 1, wherein the exit surface of the lens is arranged in a substantially rectangular shape.

6. The vehicle lighting module according to claim 1, wherein the exit surface of the lens comprises a plurality of optical elements configured to shape the collimated light pattern into a low-beam light pattern.

7. The vehicle lighting module according to claim 1, wherein the exit surface of the lens comprises a plurality of optical elements configured to shape the collimated light pattern into a high-beam light pattern.

8. The vehicle lighting module according to claim 1, wherein the collimated light pattern is suitable for a vehicular lamp from the group consisting of fog, low-beam, high-beam, static bending and daytime running lamps.

9. A vehicle headlamp assembly, comprising:

a plurality of vehicle lighting modules, each module comprising a lens with an input and exit surface, and an LED light source position to direct incident light into the input surface; and

a case housing the modules,

wherein the input surface comprises a plurality of lens elements configured to shape at least 60% of the incident light into a collimated light pattern emanating from the exit surface, each element having a different focal length.

10. The vehicle headlamp assembly according to claim 9, wherein the case has a substantially rectangular cuboid shape.

11. The vehicle headlamp assembly according to claim 9, wherein the light source and the exit surface of the lens, associated with each vehicle lighting module, collectively define a depth of approximately 50 millimeters or less.

12. The vehicle headlamp assembly according to claim 9, wherein the light source and the exit surface of the lens, associated with each vehicle lighting module, collectively define a depth of approximately 25 millimeters or less.

13. The vehicle headlamp assembly according to claim 9, wherein the exit surface of the lens associated with each vehicle lighting module is arranged in a substantially circular shape.

14. The vehicle headlamp assembly according to claim 9, wherein the exit surface of the lens associated with each vehicle lighting module is arranged in a substantially rectangular shape.

15. The vehicle headlamp assembly according to claim 9, wherein the exit surface of the lens associated with each vehicle lighting module comprises a plurality of optical elements configured to shape the collimated light pattern.

16. The vehicle headlamp assembly according to claim 10, wherein the case has a height-to-width aspect ratio of approximately 1:

8.

17. The vehicle headlamp assembly according to claim 10, wherein the case has a height-to-width aspect ratio of approximately 1:

4.

18. The vehicle headlamp assembly according to claim 10, wherein the case has a height of approximately 20 to 55 mm, a width of approximately 150 to 200 mm, and a depth of approximately 20 to 55 mm.