Headlamp assembly with isolated optics chamber

• US 20080239743A1
• Filed: 03/29/2007
• Published: 10/02/2008
• Est. Priority Date: 03/29/2007
• Status: Active Grant

• Current Assignee: Magna International Incorporated
• Original Assignee: Magna International Incorporated
• Inventors: Lambert, Chad D., McFadden, James R.
• Granted Patent: US 7,806,572 B2
• Time in Patent Office: Days
• US Class Current: 362/512
• 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 45/33 specially adapted for headlamps
• CPC Class Codes: F21S 45/43 using gas
• CPC Class Codes: F21S 45/47 Passive cooling, e.g. using fins, thermal conductive elements or openings
• CPC Class Codes: F21S 45/48 with means for conducting heat from the inside to the outside of the lighting devices, e.g. with fins on the outer surface of the lighting device
• CPC Class Codes: F21S 45/50 Waterproofing
• CPC Class Codes: F21V 29/74 with fins or blades
• CPC Class Codes: F21V 29/763 the planes containing the fins or blades having the direction of the light emitting axis
• CPC Class Codes: F21V 29/83 the elements having apertures, ducts or channels, e.g. heat radiation holes
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]

Abstract

A headlamp assembly which employs semiconductor light sources includes an optics chamber that is isolated from the surrounding environment to prevent the ingress of water, dirt, or other foreign materials into the optics chamber. At the same time, the headlamp assembly includes a plenum chamber, separated from the optics chamber, and airflow through the plenum chamber provides the necessary cooling for the semiconductor light sources.

Claims

1. A headlamp assembly, comprising:

a base member;

a transparent cover member joined to the base member;

a light engine housing including;

a light engine employing semiconductor light sources;

a lens, the lens being operable to focus light from the semiconductor light sources into a desired beam pattern;

a heat rejection structure extending outside of the housing to remove heat from the semiconductor light sources;

a mounting flange and flexible bellows moveably mounting the light engine housing with respect to the base member, wherein the base member, transparent cover member and light engine housing form an optics chamber isolated from the surrounding environment; and

a rear member connected to the base member and the transparent cover member to define a plenum chamber about the heat rejection structure, the plenum chamber including at least one inlet to admit cooling air to the plenum chamber and at least one outlet to exhaust cooling air from the plenum chamber.

2. The headlamp assembly of claim 1 further comprising an aiming mechanism outside the optics chamber, the aiming mechanism being operable to position the light engine housing to aim the light beam patterns produced by the headlamp assembly.

3. The headlamp assembly of claim 2 wherein the aiming mechanism extends between the light engine housing and the rear member.

4. A headlamp assembly, comprising:

a base member;

a transparent cover member joined to the base member;

a light engine housing including;

a light engine employing semiconductor light sources;

a lens, the lens being operable to focus light from the semiconductor light sources into a desired beam pattern;

a heat rejection structure extending outside of the housing to remove heat from the semiconductor light sources; and

a mounting flange and flexible bellows moveably mounting the light engine housing with respect to the base member, wherein the base member, transparent cover member and light engine housing form an optics chamber isolated from the surrounding environment.

5. The headlamp assembly of claim 4 further comprising an aiming mechanism outside the optics chamber, the aiming mechanism being operable to position the light engine housing to aim the light beam patterns produced by the headlamp assembly.