Patent ID: 12228261

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The figures are not drawn to scale and may be simplified for clarity. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate to a vehicle light. Particularly, embodiments of present disclosure relate to a vehicle light with a split optical assembly. The term “vehicle” or other similar term used herein are inclusive of motor vehicles in general such as land vehicles, watercrafts and aircraft that are propelled by motors, which may be driven by fuels derived from resources other than petroleum, electricity, hydrogen, or combinations thereof. For example, vehicles may include passenger automobiles such as sedans, sport utility vehicles, buses, trucks, and the like, transport vehicles such as commercial fleet vehicles, industrial vehicles such as tractors, skeet gears, excavators, and the like, as well as powersports vehicles.

FIGS.1A-1Hschematically demonstrate a vehicle light100according to the present disclosure. The vehicle light100may be installed on a vehicle and used as an exterior light device for a motor vehicle. The vehicle light100is an exterior light configured to a beam pattern set forth in any current global vehicular lighting regulation, e.g., the current U.S. NHTSA a No. 108.

FIG.1Ais a schematic section view of the vehicle light100. The vehicle light100includes a base unit110and a functional optical unit108. The base unit110includes a housing102, a light source unit104disposed in the housing102, and a base optical unit106disposed in front of the light source unit104. In some embodiment, the base unit110may be a sealed unit. The base unit110is configured to output an intermediate beam pattern. The function optical unit108is over the base optical unit106of the base unit110. The function optical unit108may be designed to project the intermediate beam pattern into a target beam pattern. Different functional optical unit108may be interchangeably attached to the base unit110to generate different target beam patterns.

FIG.1Bis a schematic sectional view of the base unit110of the vehicle light100during assembly.FIG.1Cis a sectional view of the base unit110showing light paths. The base unit110is assembled by attaching the light source unit104to the housing102and sealing the base optical unit106to the housing102. As shown inFIG.1B, the housing102may include a body120. The body120defines an inner volume122and an opening124. In some embodiments, the body120may be formed from a material that is structurally strong with good heat conductivity to provide cooling to the light source unit104disposed therein. The housing102may include some cooling blades126in contact with the body120. In some embodiments, the cooling blades126and the body120may be formed in a unitary body. Alternatively, the cooling blades126may be attached to the body120. The body120may include a groove128formed around the opening124for receiving the base optical unit106.

The light source unit104may include a printed circuit board (PCB)140having one or more light source142. In some embodiments, the one or more light sources142may be one or more light-emitting (LED) diodes, laser diodes, or combinations thereof. The printed circuit board140may include drive circuits and/or control circuits to the one or more light sources142. In some embodiments, the printed circuit board140is attached to the body120such that the body120and the cooling blades126may provide cooling to the printed circuit board140and the light sources142. The printed circuit board140may be fixedly attached to the body120to position the one or more light sources142in alignment with the base optical unit106.

The base optical unit106may include a lens160. When assembled, the lens160fills the opening124of the housing102. In some embodiments, the lens160may be a unitary lens formed from molding. The lens160may be formed from rigid transparent material, such as glass and plastic, including, but not limited to polycarbonate (PC), poly(methyl methacrylate) (PMMA), polystyrene (PS), cyclic olefin polymer (COP), and cyclic olefin copolymer (COCP).

In some embodiments, the lens160may be formed from flexible transparent material, such as optical grade silicone. Optical silicone is rubber-like, soft and flexible. Optical silicone can be molded accurately in a large format optic in a single mold process. Optical silicone optics are formed with a thermoset process, which utilizes a catalyst along with heat input to cure the optic into its final configuration. Rather than shrink, optical silicone effectively expands during the molding process, thereby enabling a highly accurate replication of the optical surface, including very thin optical elements in a single molding step. Additionally, optical silicone has a significantly higher temperature resistance than other common optical-grade plastics. The higher temperature resistance makes the optical silicone particularly suitable in LED applications where the optical element and the LED source has close proximity. Silicone optics may be placed directly over high temperature LED light sources, thereby significantly improving optical performance while precluding temperature degrading over time. In some embodiments, the adhesive130may be omitted when the lens160is formed from a flexible material, such as silicone.

The lens160may be shaped to achieve a desired optical function. The lens160may have an input surface166and an exit surface164. The input surface166and the exit surface164may be formed on opposite sides of the lens160. When assembled, the input surface166faces the light source142and the exit surface164faces an exterior of the housing102. In some embodiments, the input surface166may include various sections to collect light rays144from the light source142. In some embodiments, the lens160may include one or more reflective surfaces165configured to reflect light rays bouncing within the lens160towards the exit surface164. In some embodiments, a mirror coating may be formed on the reflective surfaces165to improve transmission efficiency of the lens160. When assembled, the input surface166surrounds the light source142. The reflective surfaces165may be disposed within the housing102. When assembled, the exit surface164is positioned in the opening124formed through the exterior of the housing102. The exit surface164may include one or more sections. In some embodiments, the exit surface164may include a top section164t. The top section164tmay be a planar surface.

In some embodiments, the lens160may include a connection feature168shaped to position the lens160in a target location of the housing102. In some embodiments, the connection feature168may be an outer rim configured to fit with the groove128in the housing102. When the connection feature168is inserted in the groove128, the light source142is aligned with an optical axis161of the lens160. In some embodiments, the connection feature168and the housing102form a sealed connection so that the light source142and the printed circuit board140are sealed within the housing102. In some embodiments, an adhesive130may be applied to the groove128and/or the connection feature168prior to inserting the connection feature168into the groove128. The adhesive130would cure and form an airtight and watertight connection between the lens160and the housing102. Alternatively, the adhesive130may be replaced by any suitable sealing means, such as a sealing ring secured therein.

After assembled, the base unit110, which includes the housing102, the light source unit104and the base optical unit106, form a sealed unit. In some embodiments, the base unit110is configured to project the light rays144from the light source142to an intermediate beam pattern. In some embodiments, the intermediate beam pattern may be a bunch of parallel beams. In some embodiments, the bunch of parallel beams may be along the optical axis161of the lens160.

FIG.1Cschematically illustrates the light paths within the base unit110from the light rays144to exit beams146. The exit beams146form the intermediate beam pattern with a bunch of parallel beams.

The base optical unit106and the function optical unit108according to embodiments of the present disclosure form an optical assembly to achieve a target beam pattern. Even though the base optical unit106described above is designed to project parallel beams and the function optical unit108is designed to distribute parallel beams into the target beam pattern, the base optical unit106and the function optical unit108may be designed in any suitable arrangement to achieve the target beam pattern.

FIG.1Dis a schematic exploded view of the vehicle light100showing components of the function optical unit108. The function optical unit108includes a functional lens180. The functional lens180may be a transparent panel having an input surface182and an exit surface181. In some embodiments, the functional lens180may be an injection molding having patterns formed on at least one of the input surface182and the exit surface181to generate a target beam pattern. In some embodiments, the functional lens180may be a transparent panel in a form of sheeting. The input surface182and the exit surface181are substantially parallel to each other and may have patterns to achieve optical function. The shape, dimension, patterns, and/or surface features may be designed to distribute input beams from the input surface182to a target pattern. When assembled, the input surface182of the functional lens180faces the exit surface164of the lens160in the base unit110. The exit beams146enter the input surface182, transmit through the functional lens180, and exit the exit surface181in the target pattern.

The functional lens180may be formed from any suitable material. The functional lens180may be formed from transparent material, such as glass, plastic, including, but not limited to polycarbonate (PC), poly (methyl methacrylate) (PMMA), polystyrene (PS), cyclic olefin polymer (COP), cyclic olefin copolymer (COCP), and optical silicone. In some embodiments, when the functional lens180is formed from a flexible material, such as silicone, sealant may be omitted between the functional lens180and the body120. In some embodiments, the functional lens180and the lens160may be formed from the same material. In other embodiments, the functional lens180and the lens160may be formed from different materials. For example, the lens160may be formed from optical grade silicone, and the functional lens180may be formed from plastic. In some embodiments, the functional lens180may include suitable pigments to achieve desired color, for example, red, yellow, blue, suitable for signals, warnings, decoration, and etc.

In some embodiments, the functional optical unit108may be removably attached to the base unit110by a suitable fastening means, such as screws, clamps, bolts and nuts, adhesives, magnets, clips, threaded connection, and the like. In the embodiment ofFIG.1A, the functional lens180is attached to the base unit110by screws188. The functional lens180may include through holes or notches183. The screws188may be secured to the housing102via the through holes or notches183.

In some embodiments, the function optical unit108may include a sealing ring184disposed between the lens160and the functional lens180along an edge of the functional lens180. The sealing ring184may be formed from elastomers. The sealing ring184seals the gaps between the lens160and the functional lens180to prevent exterior elements. In some embodiments, the functional optical unit108further includes an edge ring186disposed around the functional lens180. The edge ring186may provide structural support and protection to the functional lens180.

In some embodiments, two or more functional lens180may be packaged with one base unit110, allowing the vehicle light100to function as different vehicle lights. In some embodiments, the functional lens180may include notches or markers for easy alignment during installation and replacement. The fastening means, such as the screws188, may be designed for repeated tightening and loosening, thereby, switching or replacing the function lens180as needed.

As discussed above, optical assembly of the vehicle light100is split into the lens160in the base unit110and the functional lens180. The lens160transmits the light rays144from the light source142into an intermediate pattern and the functional lens180transmits the intermediate pattern to a target pattern. The functional lens180in the functional optical unit108may be changed to obtain different beam pattern or a different color.

The vehicle light100may be configured to perform various functions, such as stop lamp functions, tail lamp functions, headlamp functions, daytime running light functions, dynamic bending light functions, and fog lamp functions. Many of these functions, such as headlamp functions, are governed by government standards and requirements for safety reasons. In particular, government standards may require vehicle lights to irradiate certain beam patterns according to the lighting function. A beam pattern is a spatial distribution of beam intensity. For example, a vehicle headlamp must irradiate a low beam pattern or a high beam pattern to secure the driver's view ahead of the vehicle in a low light condition. The headlamp normally maintains the low beam pattern to prevent a dazzle effect of the drivers of oncoming vehicles driving in the opposite direction or the drivers of preceding vehicles. During high-speed driving or in a low light area, the headlamp forms the high beam pattern to ensure safe driving.

By choosing different target patterns, the vehicle lights100according to the present disclosure may be used as headlamps, auxiliary driving lamps, or front fog lamps. The target pattern is achieved using the combination of the lens160in the base unit110and the functional lens180disposed over the base unit110. The corresponding target patterns meet the corresponding government standard. For example, the vehicle light100may be used as headlamps when the lens160and the functional lens180generate a target pattern meets a government standard, such as current U.S. NHTSA Motor Vehicle Safety Standard No. 108. Alternatively, the vehicle light100may be used as an auxiliary driving lamp when the lens160and the functional lens180generate a beam pattern that meets SAE standard J581 for Auxiliary Upper Beam Lamps. The vehicle light100may be used as a front fog lamp when the lens160and the functional lens180generate a beam pattern that meets the SAE Standard J583 for Front Fog Lamp.

Conventional vehicle lights include a light source and an optical assembly to generate a target beam pattern from the light source. For exterior lighting devices, the light source and the optical assembly are typically sealed or otherwise permanently attached to protect the light source from environment elements. As a result, vehicle lights have fixed functions, and the light source and the optical assembly are replaced together. The functional lens180in the functional optical unit108may be replaced and changed independently from the base unit110, therefore, providing flexibility and reducing cost of ownership.

The split lens configuration provides flexibility to the vehicle light100. By applying different functional lens180over the same base unit110, the vehicle light100may project different target patterns and/or different colors to function as desired.FIGS.1E-1Hschematically demonstrate the vehicle light100with two different target patterns.

FIG.1Eis a schematic view of the vehicle light100with the functional lens180designed to generate a low beam pattern152. In the embodiment ofFIG.1E, the functional lens180is designed to transmit the intermediate pattern from the base unit110to light beams148which form the low beam pattern152at a vertical plane150in front of the vehicle light100.

FIG.1Fschematically illustrates the low beam pattern152regulated by government standards so that the light from the low beam pattern152is focused on the proper position and does not create glare or a safety hazard for oncoming traffic. For example, the low beam pattern152illuminates the road and surroundings ahead of a vehicle when meeting or closely following other vehicles. Most standards require that the low beam pattern152projects an asymmetrical pattern to provide adequate forward and lateral illumination and control glare by limiting light directed towards preceding or oncoming drivers.

FIG.1Gis a schematic view of the vehicle light100with a functional lens180adesigned to generate a fog pattern154. In the embodiment ofFIG.1G, the functional lens180ais designed to transmit the intermediate pattern from the base unit110to light beams148awhich form the fog pattern154at a vertical plane150ain front of the vehicle light100.FIG.1Hschematically illustrates the fog pattern154regulated by government standards so that the light from the fog pattern154is randomly distributed at a wide symmetrical range in front of a vehicle.

The split lens configuration also extends lifespan of the vehicle light100. Since the functional lens180is disposed over the base unit110, the lens160and the light source unit104are removed from the exterior elements, such as dust, particle, moisture, extreme temperatures, highspeed foreign debris during driving, therefore, are unlikely to be damaged during operation. In case the functional lens180is damaged, the vehicle light100may be easily repaired by replacing a new functional lens while the base unit110may take advantage of the long lifespan of the LED light source.

Even though the base optical unit106described above includes the lens160, the base optical unit106may include reflectors, lenses, or a combination thereof.FIG.2schematically demonstrates a vehicle light200according to the present disclosure. The vehicle light200is similar to the vehicle light100except that the vehicle light200includes a base unit210having a base optical unit206in place of the base optical unit106. The base optical unit206includes a reflecting cup260and a transparent cover262. The reflecting cup260is attached to the housing102so that the light source142is aligned with an optical axis261of the reflecting cup260. The reflecting cup260opens towards the opening124. The transparent cover262be disposed over the reflecting cup260. The transparent cover262may include a rim268shaped to match the groove128of the housing102. The rim268of the transparent cover262may be inserted in the groove128in the body120to seal the base unit210. Different functional lens180may be attached to the base unit210to generate different beam patterns.

Even though the vehicle light100or200includes one light source and one set of optical devices, embodiments of the present disclosure may be applied to complex lights, which include two or more light sources with corresponding optical devices. An exemplary complex light including four light sources, also known as quad light, is described inFIGS.3A-3I.

FIGS.3A-3Ischematically demonstrates a vehicle light300according to the present disclosure. Similar to the vehicle lights100and200, the vehicle light300also includes the split lens configuration according to the present disclosure. The vehicle light300may be used as an exterior light and configured to a beam pattern set forth in any current global vehicular lighting regulation.

FIG.3Ais a perspective front view of the vehicle light300when fully assembled.FIG.3Bis a perspective back view of the vehicle light300.FIGS.3C and3Dare exploded views of the vehicle light300.FIG.3Eis a schematic view of a base unit of the vehicle light300.FIG.3Fis a schematic exploded view of the function optical unit of the vehicle light300.FIG.3Gis a schematic front view of the vehicle light300.FIGS.3H and3Iare schematic sectional views of the vehicle light300along the lines3H-3H and3I-3I ofFIG.3Grespectively.

The vehicle light100includes a base unit310and a functional optical unit308. The base unit310includes a housing302, a light source unit304disposed in the housing302, and a base optical unit306disposed in front of the light source unit304. The light source unit304includes four light sources in a two-by-two arrangement. The base optical unit306includes four sets of optic devices corresponding to the four light sources. In some embodiment, the base unit310may be a sealed unit. The base unit310projects intermediate beam patterns from the four light sources. The function optical unit308is disposed over the base optical unit306of the base unit310. The function optical unit308may be designed to project the intermediate beam patterns into a set of target beam patterns.

The base unit310is assembled by attaching the light source unit304to the housing302and sealing the base optical unit306to the housing302. The housing302may include a body320. The body320defines an inner volume322and an opening324. In some embodiments, the body320may be formed from a material that is structurally strong with good heat conductivity to provide cooling to the light source unit304disposed therein. The housing302may include some cooling blades326in contact with the body320. In some embodiments, the cooling blades326and the body320may be formed in a unitary body. The body320may include a groove328formed around the opening324for receiving the base optical unit306. In some embodiments, the housing302may include a mounting bracket330configured to mount the vehicle light300on a vehicle.

The light source unit304may include a printed circuit board (PCB)340having four light sources342. In some embodiments, each of the four light sources342may include one or more LED diodes, laser diodes, or combinations thereof. The four light sources342may be identical or different depending on the function of the vehicle light300. The printed circuit board340may include drive circuits and/or control circuits to the light sources342. In some embodiments, the four light sources342may be independently controlled. A cable344may be connected to the printed circuit board340to provide power and control signal to the light sources342. In some embodiments, the printed circuit board340is attached to the body320such that the body320and the cooling blades326may provide cooling to the printed circuit board340and the light sources342. The printed circuit board340may be fixedly attached to the body320to position the four light sources342in alignment with the base optical unit306.

The base optical unit306may include a lens set360. When assembled, the lens set360fills the opening324of the housing302. In some embodiments, the lens set360may include four lenses. In some embodiments, the four lenses of the lens set360may be connected into a unitary body. The lens set360may be formed by molding. The lens set360may be formed from transparent material, such as glass and plastic, and optical silicone.

The lenses in the lens set360may be shaped to achieve desired optical functions. The lenses in the lens set360may be identical to each other or different from one another depending on the design. Each lens may have an input surface366and an exit surface364. The input surface366and the exit surface364may be formed on opposite sides of the lens set360. When assembled, the input surface366faces the light sources332and the exit surface364faces an exterior of the housing302. In some embodiments, the lens set360may include an alignment marker370. The alignment marker370is used to align the lens of the lens set360with the corresponding light sources342. The exit surface364may include one or more sections. In some embodiments, the exit surface364may include a top section364t. The top section364tmay be a planar surface.

In some embodiments, the lens set360may include a connection feature368shaped to position the lens set360in a target location of the housing302. In some embodiments, the connection feature368may be an outer rim configured to fit with the groove328in the housing302. When the connection feature368is inserted in the groove328, the light sources342are aligned with the corresponding lens of the lens set360. In some embodiments, the connection feature368and the housing302form a sealed connection so that the light sources342and the printed circuit board340are sealed within the housing302. In some embodiments, an adhesive may be applied to the groove328and/or the connection feature368prior to inserting the connection feature368into the groove328. The adhesive would cure and form an airtight and watertight connection between the lens set360and the housing302.

After assembled, the base unit310, which includes the housing302, the light source unit304and the base optical unit306, form a sealed unit.FIG.3Eis a schematic view of the base unit310. The base unit310is configured to project light rays from the light sources342to the intermediate beam patterns. In some embodiments, the intermediate beam pattern may be a bunch of parallel beams.

FIG.3Fis a schematic exploded view of the function optical unit308. The function optical unit308includes a functional lens380. The functional lens380may be a transparent panel having an input surface382and an exit surface381. The functional lens180may be an injection panel having a shape to match the shape of the body320. The shape, dimension, patterns, and/or surface features may be designed to distribute input beams from the input surface382to target patterns. In some embodiments, the functional lens380may include different lens designs for the four light sources342. In some embodiments, the functional lens380may have alignment marks385to align the lens patterns of the function lens380with the corresponding light source342. When assembled, the input surface382of the functional lens380faces the exit surface364of the lens set360in the base unit310. The exit beams enter the input surface382, transmit through the functional lens380, and exit the exit surface381in the target patterns.

The functional lens380may be formed from any suitable material. =The functional lens380may be formed from transparent material, such as glass, plastic, including, but not limited to polycarbonate (PC), poly (methyl methacrylate) (PMMA), polystyrene (PS), cyclic olefin polymer (COP), cyclic olefin copolymer (COCP), and optical silicone. In some embodiments, the functional lens380and the lens set360may be formed from the same material. In other embodiments, the functional lens380and the lens set360may be formed from different materials. For example, the lens set360may be formed from optical grade silicone, and the functional lens380may be formed from plastic. In some embodiments, the functional lens380may include suitable pigments to achieve desired color, for example, red, yellow, blue, suitable for signals, warnings, decoration, and etc.

In some embodiments, the functional optical unit308may be removably attached to the base unit310by a suitable fastening means, such as screws, clamps, bolts and nuts, adhesives, magnets, clips, threaded connection, and the like. In the embodiment ofFIGS.3A-3B, the functional lens380is attached to the base unit310by screws388. The functional lens380may include through holes or notches383. The screws388may be secured to the housing302via the through holes or notches383.

In some embodiments, the function optical unit308may include a sealing ring384disposed between the lens set360and the functional lens380along an edge of the functional lens380. The sealing ring384may be formed from elastomers. The sealing ring384seals the gaps between the lens set360and the functional lens380to prevent exterior elements. In some embodiments, the functional optical unit308further includes an edge ring386disposed around the functional lens380. The edge ring386may provide structural support and protection to the functional lens380.

In some embodiments, the vehicle light300may switch between different functions/patterns, such as between a low beam drive pattern and a fog pattern, between an auxiliary upper beam pattern and a front fog pattern, between a front fog beam pattern and a signal pattern, between a low beam pattern and a signal pattern, or between a low beam pattern and a high beam pattern, or the like, by selective lighting different ones of the light sources342.

In some embodiments, two or more functional lens380may be packaged with one base unit310, allowing the vehicle light300to function as different vehicle lights. In some embodiments, the functional lens380may include notches or markers for easy alignment during installation and replacement. The fastening means, such as the screws388, may be designed for repeated tightening and loosening, thereby, switching or replacing the function lens380as needed.

As discussed above, optical assembly of the vehicle light300is split into the lens set360in the base unit310and the functional lens380. The lens set360transmits the light rays from the light source342into the intermediate patterns and the functional lens380transmits the intermediate patterns to target patterns. The functional lens380in the functional optical unit308may be changed to obtain different beam patterns or a different color.

While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof.