Abstract

Low optical efficiency of light-emitting diode (LED) based headlamp is one of the most important issues to obstruct applications of LEDs in headlamp. An effective high-efficient LED headlamp freeform lens design method is introduced in this paper. A low-beam lens and a high-beam lens for LED headlamp are designed according to this method. Monte Carlo ray tracing simulation results demonstrate that the LED headlamp with these two lenses can fully comply with the ECE regulation without any other lens or reflector. Moreover, optical efficiencies of both these two lenses are more than 88% in theory.

© 2010 OSA

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References

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  1. A. Mills, “Solid state lighting-a world of expanding opportunities at LED 2002,” III-Vs Rev. 16(1), 30–33 (2003).
    [CrossRef]
  2. A compilation of motor vehicle crash data from the fatality analysis reporting system, US Department pf transportation (2001).
  3. T. Luce, “LED Headlamps – The Spiny Path to a Legal Headlamp,” Proc. SPIE 5663, (2005).
  4. A. Cvetkovic, O. Dross, J. Chaves, P. Benitez, J. C. Miñano, and R. Mohedano, “Etendue-preserving mixing and projection optics for high-luminance LEDs, applied to automotive headlamps,” Opt. Express 14(26), 13014–13020 (2006).
    [CrossRef] [PubMed]
  5. A. Domhardt, U. Rohlfing, and S. Weingaertner, “New design tools for LED headlamps,” Proc. SPIE7003, (2008).
  6. United Nations Economic Commission for Europe vehicle regulations, Reg. 112-Rev. 2.
  7. A. Domhardt, S. Weingaertner, U. Rohlfing, and U. Lemmer, “TIR optics for non-rotationally symmetric illumination design,” Proc. SPIE7103, (2008).
  8. J. L. Alvarez, M. Hernandez, P. Benitez, and J. C. Minano, “TIR-R Concentrator: a new compact high-gain SMS design,” Proc. SPIE4446, (2002).
  9. F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
    [CrossRef]
  10. L. W. Sun, S. Z. Jin, and S. Y. Cen, “Free-form microlens for illumination applications,” Appl. Opt. 48(29), 5520–5527 (2009).
    [CrossRef] [PubMed]
  11. K. Wang, F. Chen, Z. Y. Liu, X. B. Luo, and S. Liu, “Design of compact freeform lens for application specific Light-Emitting Diode packaging,” Opt. Express 18(2), 413–425 (2010).
    [CrossRef] [PubMed]
  12. F. Chen, K. Wang, Z. Y. Liu, X. B. Luo, and S. Liu, “Freeform lens for application-specific LED packaging,”Proc. International Conference on Electronic Packaging Technology & High Density Packaging (ICEPT-HDP), 443–447 (2009).
  13. For data sheet of OSRAM OSTAR® headlamp LED, see http://www.osram-os.com .
  14. O. Dross, R. Mohedano, P. Benitez, J. C. Minano, J. Chaves, J. Blen, M. Hernandez, and F. Munoz, “Review of SMS methods and real word applications,” Proc. SPIE5529, (2004).

2010

2009

2006

2004

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

2003

A. Mills, “Solid state lighting-a world of expanding opportunities at LED 2002,” III-Vs Rev. 16(1), 30–33 (2003).
[CrossRef]

Beni´tez, P.

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

Benitez, P.

Cen, S. Y.

Chaves, J.

Chen, F.

Cvetkovic, A.

Dross, O.

A. Cvetkovic, O. Dross, J. Chaves, P. Benitez, J. C. Miñano, and R. Mohedano, “Etendue-preserving mixing and projection optics for high-luminance LEDs, applied to automotive headlamps,” Opt. Express 14(26), 13014–13020 (2006).
[CrossRef] [PubMed]

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

Jin, S. Z.

Liu, S.

Liu, Z. Y.

Luo, X. B.

Mills, A.

A. Mills, “Solid state lighting-a world of expanding opportunities at LED 2002,” III-Vs Rev. 16(1), 30–33 (2003).
[CrossRef]

Miñano, J. C.

A. Cvetkovic, O. Dross, J. Chaves, P. Benitez, J. C. Miñano, and R. Mohedano, “Etendue-preserving mixing and projection optics for high-luminance LEDs, applied to automotive headlamps,” Opt. Express 14(26), 13014–13020 (2006).
[CrossRef] [PubMed]

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

Mohedano, R.

Muñoz, F.

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

Parkyn, B.

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

Sun, L. W.

Wang, K.

Appl. Opt.

III-Vs Rev.

A. Mills, “Solid state lighting-a world of expanding opportunities at LED 2002,” III-Vs Rev. 16(1), 30–33 (2003).
[CrossRef]

Opt. Eng.

F. Muñoz, P. Benı́tez, O. Dross, J. C. Miñano, and B. Parkyn, “Simultaneous multiple surface design of compact air-gap collimators for light emitting diodes,” Opt. Eng. 43(7), 1522–1530 (2004).
[CrossRef]

Opt. Express

Other

F. Chen, K. Wang, Z. Y. Liu, X. B. Luo, and S. Liu, “Freeform lens for application-specific LED packaging,”Proc. International Conference on Electronic Packaging Technology & High Density Packaging (ICEPT-HDP), 443–447 (2009).

For data sheet of OSRAM OSTAR® headlamp LED, see http://www.osram-os.com .

O. Dross, R. Mohedano, P. Benitez, J. C. Minano, J. Chaves, J. Blen, M. Hernandez, and F. Munoz, “Review of SMS methods and real word applications,” Proc. SPIE5529, (2004).

A compilation of motor vehicle crash data from the fatality analysis reporting system, US Department pf transportation (2001).

T. Luce, “LED Headlamps – The Spiny Path to a Legal Headlamp,” Proc. SPIE 5663, (2005).

A. Domhardt, U. Rohlfing, and S. Weingaertner, “New design tools for LED headlamps,” Proc. SPIE7003, (2008).

United Nations Economic Commission for Europe vehicle regulations, Reg. 112-Rev. 2.

A. Domhardt, S. Weingaertner, U. Rohlfing, and U. Lemmer, “TIR optics for non-rotationally symmetric illumination design,” Proc. SPIE7103, (2008).

J. L. Alvarez, M. Hernandez, P. Benitez, and J. C. Minano, “TIR-R Concentrator: a new compact high-gain SMS design,” Proc. SPIE4446, (2002).

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Figures (14)

Fig. 1
Fig. 1

Low-beam pattern on the measuring screen provided by ECE R112 Regulation (reproduced from reference 6).

Fig. 2
Fig. 2

Sketch diagram of gradient of the horizontal cut-off line.

Fig. 3
Fig. 3

Sketch diagram of lens’ structure.

Fig. 4
Fig. 4

Calculation of the points on the inner surface’s curve.

Fig. 5
Fig. 5

Calculation of the points on the TIR surface’s curve.

Fig. 6
Fig. 6

Control of the incident collimating rays.

Fig. 7
Fig. 7

Sketch diagram of meshing the target plane.

Fig. 8
Fig. 8

Calculation of the freeform surface.

Fig. 9
Fig. 9

Cross section of the low-beam lens and LED.

Fig. 10
Fig. 10

(a)Simulated illuminance distribution on the measuring screen, (b) vertical sectional curve.

Fig. 11
Fig. 11

(a)Low-beam lens, (b)Schematic view of low-beam light.

Fig. 12
Fig. 12

Radii of the rounded edges of the low-beam lens facets.

Fig. 13
Fig. 13

Simulated beam pattern of low-beam lens with rounded edges.

Fig. 14
Fig. 14

(a) High-beam lens, (b) simulated beam pattern of high-beam lens on measuring screen.

Tables (3)

Tables Icon

Table 1 Simulated illumination result compared with the corresponding value of ECE R112 (Class B) for low-beam light

Tables Icon

Table 2 Simulated illumination result compared with the corresponding value of ECE R112 (Class B) for low-beam light

Tables Icon

Table 3 Simulated illumination result compared with the corresponding value of ECE R112 (Class B) for high-beam light

Equations (4)

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G = log E β log E ( β + 0.1 )
[ 1 + n 2 2 n ( O I ) ] 1 2 N = O n I
{ a 1 × N a 1 = L a 1 a 2 × N a 2 = L a 2 a 3 × N a 3 = L a 3
{ b 1 × N b 1 = L b 1 b 2 × N b 2 = L b 2

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