JPS59212803A - Lighting apparatus and manufacture thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION In more detail, a reflector is outlined to suit the desired light profile f/C, the lens is replaced with a transparent cover plate, and the cover plate is aerodynamically The desired arbitrary angle t is the one that takes the angle t.

Automotive sealed-beam headlights contain a parabolic reflector that collects light from an incandescent filament bulb and directs it to a lens. The flute transports and scatters light into a beam pattern that meets specifications set by the Society of Automotive Engineers.The standard lens has an optical Since it is a single-acting element, its position relative to the light bulb and the reflector is critical.The position of the lens should be at right angles to the light emitted from the light bulb and the reflector. is desirable, because if the lens is oriented at an angle that is λ・-1, the glare on the riser will be worse.In other words, the lens flooding will cause the riser and edge of the full 1. In many cases, it is desirable to slope the front surface of the headlight, since it produces less controlled light, so-called glare. From the optical point of view of the lens and the glare from it, it is impractical to tilt the front surface.
It is also undesirable to tilt the point 7 of style 3. It is an object of the present invention to eliminate this type of glare while retaining the benefits of tilted lenses.

US%- by Jacobsen, 153,341 and V
(U.S. Patent 1,346,268 V by Gutdori (
This shows an early attempt to manufacture a lamp with reflector optics.3. U.S. Patent No. 3.511,9 by Dorman
83 Boo Rahir (U.S. Pat. No. 4.14 by Dorman)
No. 9,277, a recent attempt was made to produce a lamp in which a desired pattern was created using a reflector. Although it meets the strict automotive specifications, there is no such thing as an i&1.

Journal of IE Niss 1976 36
Written by Tonohiyu and Joseph on pages 42 (
In the automotive lamp described in ``Computer Design of an Automotive Lamp with a Faceted Reflector'', only the reflections produce a pattern and the fluting of the lens is eliminated? The juice is divided into multiple segments (facets). As shown in Figure 12 of the second paper, there are sharp edges between the many facets, making them discontinuous. Because each facet is a paraboloid, the intersections or connections between the surfaces are not smooth.

For this reason, the manufacture of such reflectors is extremely difficult.
．． These reflectors can be made of any suitable material such as glass, plastic, or metal. As shown in FIG. 12 of the above-mentioned paper, it is extremely implausible to form a surface with connections M1''.

It is an object of the present invention to direct the light in a pattern that is adapted to the specifications of the automobile, and whose smooth, contiguously joined surface facilitates the manufacture of headlights. It is to provide a headlight repellent.

According to the present invention, A1 reflector for sealed beam headlights: The reflective surface allows the light from the bulb to pass through the transparent front cover with a matching pattern for automotive headlights.

The reflective surface is smooth and continuous, making the reflector easier to manufacture and eliminating undesirable reflector flute glare. Is it a cover because there is no flute? It can be aerodynamically oriented and offers benefits in both style and performance, which manufacturers are currently focusing on.

The headlights are manufactured using a digital computer aided process. This process involves digitally modeling and iteratively modifying the reflective surface to create a light intensity pattern that best meets automotive specifications, so that the reflective surface is smooth and quick-reading. A digitally modeled light source is used that closely resembles the light intensity from a tungsten halogen lamp.In the prior art, multiple parabolic reflectors make up the headlight. In the process, the only decision is where to direct the light from each parabolic facet, and this direction is changed accordingly to obtain the desired light pattern.In contrast, according to the VC of the present invention, A very large number, say 500,000, of light paths are defined from a precisely modeled light source to a reflective surface. The light intensity that crosses a part of the projected 12-sphere surface is determined by counting the number of rays that intersect each unit area vc.The intensity determined in this way by L is digitally 2. A performance function can be generated that shows agreement with the specifications.The shape of the reflective surface can also be modeled digitally to optimize the performance function. Each time the shape changes, the connections between the surfaces are blended and smoothed, creating sharp edges or discontinuities that are difficult to manufacture. The foregoing and other objects, features and advantages of the present invention have been fully incorporated into the detailed description and claims below.

In FIG. 1 V, an automobile headlight Ii of the present invention is shown.
C includes a light bulb 11 and a transparent front cover 12. A light bulb [1 is a filament that serves as a light source] &

The front cover 12 can be oriented at an aerodynamically desirable angle with respect to the headlights3, which means that the front cover 12 can be oriented at an angle of 15° or more, and the first
As shown in figure υζ, the order I is 45° to 50°.
I(f) means something or something desirable.

A reflector 13 surrounds the light bulb, and the reflective surface of the reflector 130, which has a honeymoon on the front cover 12, allows light from the light bulb 11 to pass through the front cover in a pattern that matches the specifications of automobile headlights. let

Figures 2 and 2A to 20 (as shown) The reflecting surface of the reflector includes a medium-heat deformed beveled ellipsoid 14 and V (two edge deformations J and ellipsoids 15 and 1).
6 is included in A1, and the edge circular surface 15 is connected to the central elliptical surface 14 by a smooth continuous connection 17.

Similarly, the edge inverted circular surface 1G is a smooth continuous connection 18
It is connected to the central elliptical surface 14.

The central surface 14 has a smooth vertical ridge 2 in the center of the scrap circular surface.
1 is added. 1 ellipsoidal surface 14 is a concave surface,
+ for headlights! Qi+ is tilted. Ellipsoid 14
．． 15 and 16 are concave surfaces, and by deforming from a true paraboloid, a predetermined light pattern is generated, and the connection between the surfaces is smooth and continuous. It is possible to adjust the length of the lamp, but this is not part of the reflective surface.According to the present invention, almost all of the reflective surface is -edges are avoided.'Ciro6゜2: 3 ta i'This shows the computer-aided Radical process for manufacturing this type of reflector.Before explaining Fig. 3, we will explain Fig. Figure 4 depicts a prior art reflector to illustrate the advantages of the present invention.

ul: Figure 4 shows an attempt to reduce the depth of the reflector by using multiple VC paraboloids instead of a single paraboloid at conventional technology +/(m. Note 1 - Things to do The connections 23 and 24 between the paraboloids are sharp edges, which are not modeled, and the manufacturing force "2j!I
L/I. Furthermore, the 111S portion between 2:3 and 25 and between 24 and 26 of the reflection is shadowed.
Reflection of light r (does not contribute. In the reflector of Fig. 4, the connection 2
3 and "' modulus a> Hector goes to 7. If you change it, the small radius of curvature is Jl in conjunction 23 and 2.1
-Always small. The slope of the surface is discontinuous. That is, the minimum radius of curvature is arbitrarily small. As used in the present invention, the sliding and continuous connections are shown at 23 and 24 in FIG.
The condition depicted in does not exist, meaning that the normal is always well defined.

When the shape includes separate reflector surfaces, such as the reflector of FIG. 2, the connections between the surfaces are treated as some other region. The resulting first strength calculation includes the effects of smooth articulation. The articulation is therefore sufficiently large to facilitate the glass forming process. If the minimum radius of curvature is 1.27 mm, if it is smaller than this, there will be a problem in forming the glass into a sharp edge. , the invention can be practiced on smooth, articulated surfaces having a minimum radius of curvature greater than about 127 mm.

The conventional technology ignores the reflection from the connection3, and the conventional technology lamp has an unlucky reflective surface.
+- V as in the paper by Nohu et al. and FIG. 4 of this specification.
C) has a discontinuous inclination due to surface connection (Thoman's patent).

Since the prior art does not deal with articulations, the articulations of actual products must be kept as sharp as possible9. That is, the minimum radius of curvature cannot be made arbitrarily small and there is no hana.The present invention The problem with the reflector & (bacco) is that the shape may be selected so that the minimum radius of curvature is large in the connection.

The computer-assisted process of the present invention also includes step 27 of inputting a predetermined light pattern into a digital computer to digitize it. In the example currently being described, the Nissin Nii specifications are Nissin Nii Journal 579 C, January 1940, approved by the Lighting Department, 197
IJ (December 4), IJ Committee Latest Revised 23.31 True Table 1, [Finch (178mm) Type 2 Sealed Beam Mount F6' 1j Bubbles Test Point Sen J l/c i
J<sλ'1.

As shown in 28, specify the clothes 1n1 of the reflector 1
- is digitized as a numerical shape function, and given manually to a digital computer B'. The modified ellipse [f+1 is 3, the coefficients of these ellipsoids are parameters modified to fit the light pattern specification V(π), and VC between the edges of the ellipsoid to produce a smooth and continuous connection. The optimization steps for these coefficients are shown in 29.
3Of/(: the selection of the well-known coefficient combinations of the shape function shown and the calculation of the filtered light intensity using this reflector shape along with multiple light paths).

31, a digital Φcomputer model of a tungsten halogen lamp with a glow (as shown in Figure 5, this model (/( is a
The broken filament 32 does not contain: l' stiffness, and by-products are distributed in its longitudinal direction.
The resulting ray is modeled as an opaque end cap, a quartz cylinder 33, and is refracted through the envelope by ti(+L).

As shown in Figure 34, the light intensity from this digital model lamp is created by the light path resting on the envelope surface β71f + h. Then, determine whether or not 1 intersects the reflector. If it does not, the ray is projected directly onto the sphere surrounding the reflector. U, point 3 in Figure 6
In the 11th case where the rays intersect, it is projected onto the surface of the sphere surrounding the reflection. For example,
The light beam reflected at 35 intersects the sphere at point 36, and the actual intensity is determined only for the 300 x 8° screen on the sphere. This screen is 37 in Figure 6 of Ki 6.
The intensity is determined by counting λ′f on the unit surface (7 degrees of likelihood; the intensity is determined by counting λ′f). Again, in Figure 3, step 38 is the reflection model and reflector. This shows the creation of a ray list for the sphere -L around.In order to specify the ray path of the reflected ray, the reflected iH
At the intersection with j, l (e.g., point 35 in Figure 6), find the ``perpendicular application 1 theory 317, therefore, 3, digital computer step 28. 29 and 30 reflections l.
Use the explanation of :; to look at the normal line at the intersection.

The actual reflector is modeled according to the present invention by an inaccuracy V(1), this distortion ('; I allows the plane normal to vary around the theoretical shape VC). First, to match the gap measurements to the model predictions of the previous design.A value of 2a = 1° was chosen for use in this model from VC.Using this distorted normal and the incident light powder, The reflected rays are finally calculated.

Light II! From the tracing of the l-path, the light intensity starting at 1
It is determined as shown in the table 39. This is done by counting the number of light beams that intersect each unit plane fPK on the spherical screen.

These values are compared to a predetermined pattern as shown in IIO-C5. For each shape tried, I)
A performance factor called F U N is determined by A3. This performance factor is a measure of how much A1 the 11σ degree pattern of 9 kJ light conforms to the Niss Ni E specification V (V) to the shape under test. .

Steps 30, 38, 39 and 40 are repeated for different shapes, ie different surface coefficients. 41V (shown
-Y5 vc1 Nine predetermined patterns VC A shape that generates the most suitable light intensity is determined. This is done by selecting the set of coefficients that has the minimum value of the optimal performance function, in this case l/(P A combination of coefficients is selected.

This coefficient kJJVc vs. For each point of the exam, the canterai of 60 feet [1! is a strike. 26
σ) Test point 0) Only test point 25 has a value of 771 outside the specification. In the present example, a reflector surface that approximately satisfies the varnish, ni, and 2 a ends was created.

From the printout created in step 43 of Figure 3, the designer can determine that he or she must create a pattern with a good light intensity distribution. It is possible to repeat the process for different shape functions that can be selected. The designer can also choose which coefficients to change in the process.

From the iterations of this process, the best shape is selected, as shown at 44yc in FIG. This shape is used in the manufacture of reflectors.

Figure 7 shows the reflection 2 created by this process:
It shows a candela diagram of the Kokyo 1 prefecture pattern, which was created by a single compiler for Umiko. FIG. 7 shows a low beam pattern, and FIG. 8 shows a high beam pattern. In these figures, the dotted lines are contour pure at 2000 candela and the solid lines are contour pure at 10,000 candela. That is, in FIG. 7, the lodging height 45 represents 2,000 cantera, the constant height &j46 represents 24,000 candela, and the equal height pure between them represents the intermediate cantera value.

In Figure 7, the beam turn is moved to the lower right, as required by the automobile specifications. In the high beam turn shown in Fig. 8, a wide high-intensity beam is created.
It has been moved slightly to the lower right, as requested by automobile specifications.

For example, the computer program is Univac 1.1.
As with all computer programs that run on a 00/)it computer, this computer program should not be expected to run without normal technical execution.

This program includes a number of subroutines, and the steps shown in Figure 3 are all executed as follows. .

Safruchi/ENV corresponds to step 311 and models a tungsten-no-logen lamp.

This writes the position and direction of the ray to a file. This involves modeling the radiation from a cylinder with temperature distribution in the axial direction, and then determining the filament's radiance, the end e-cap's 70mm diameter, and the envelope's refraction.

Subroutine RUN corresponds to step 29 and is the main program for optimization. This calls subroutine OP'l''-2.

The subroutine OPT corresponds to steps 30 and 41 and is a multivariable optimizer. This is vector XNBXT
Search for the minimum value of the performance function 1) 1;'' UN by varying the performance function 1). Find the local minimum value of the performance index by iterating twice.This yields the best set of coefficients for a given shape function.This subroutine attempts to minimize the performance function.Subroutine OP T
2 takes out Zabruchino Pt”tJN for 11.

Subroutine J) F (JN is reflection and performance-related →) - The co-subroutine ■ that runs the broutine is also AYI (, corresponds to step 38,
Model reflection. This subroutine takes a ray from the file, finds the intersection of the ray with the reflector, and
Find all the normals at the intersection, warp the normal, find all the reflected rays from the warped normal, then cast the rays on the sphere 6-0 feet and 25 feet away from the reflector.Finally, this subroutine will do this at the intersection. into another file.

Subroutine ZVAL corresponds to step 28 and describes the entire shape of the reflecting surface. Subroutine ZVA L&, J,
When X, Y, 8 are given, return Z, ,Z
The call to VAL yields eight coefficients Sk with the
dY After all evaluations, we can find the 1iii human face normal gold. Although two off-axis ellipsoids with a mixing region in between are shown, other shapes may be used.

The edge shape function Z1 is in the range from =371° to =L45'' and from 1./15'' to 37°. -This shape reflects the light from the lamp to the high intensity parts of the pattern. Modify this shape using three of the eight coefficients.

In the interval from −1,2 “′ to 1.2”, the medium heat shape function Z2
-1 Use. This spreads across the principal gold square 1)-1 on the horizontal line. The remaining five staff members tJ Kako (7)
Shape k 1lrlJ ′rAl.

In the section from -1,45'' to -1211'';hi12'' to 1.45'', the shape is K, which is the smooth sum of Zl and Z2.

A function is arbitrarily selected to describe all the general shapes that the designer thinks will give a good intensity distribution.The designer then selects all the changes in the coefficients that are allowed. The process of function selection is trial and error.2 The selected function is put into ZVAL and the resulting intensity distribution is found. (H) If the designer likes the result, the coefficients are optimized / Become. If not, the instructor tries another shape.'0 The subroutine NOT%M finds the l-normal of the unit surface at the intersection.

The subroutine 5CAT warps around the normal=INORM value with a Novus distribution.

The routine l(, J', P L finds the unit reflected ray for the incident ray and the distorted normal.

The subroutine CIJ reads all sphere intersections from the file, and for both spheres I72° at the 3Q'X8' part.
The filament power is set for each subroutine l-'E R1'', which performs a complete comparison of the model cd value with the NIS specification and returns the performance index for the given configuration. The values of the coefficient set used to create the reflector in Figure 2 are as follows: S[],...,8]-C,0814,,1730,2706,,07733,
, 2i-in.

16913, 1.9259.1.6351] All the embodiments of the automobile headlight have been illustrated and explained above, but it is possible to make various modifications within the true spirit and scope of the present invention. The invention is a lighting system for dental lights, street lights, home lighting, commercial lighting, etc.! fIc equally applicable DI
This is because fib. Therefore, the scope of the claims is intended to include all such modifications.

[BRIEF DESCRIPTION OF THE DRAWINGS] Fig. 1 is a side view of the reflector enclosed in a transparent cover plate, Fig. 2 is a perspective view of the reflector, Figs. 2A to 20 r/i , respectively a front view, a top sectional view, and a side sectional view of a reflector according to the present invention; Fig. 3 is a 70-chart of the computer aided process for manufacturing the entire head lug; Fig. 1 is a prior art technique. Figures 5 and 6 are perspective views showing models generated by the titanium computer of the light source and reflector i+M (Figure 6 shows the intersection of the light ray and the spherical surface). 7 is a diagram of the low beam pattern produced by the reflector according to the invention, and FIG. 8 is a power diagram of the high beam pattern produced by the reflector according to the invention. Light bulb 12...Front cover 13...Reflector 14...
・Central ellipsoidal surface 15 + 16... Edge ellipsoidal surface 17.18 Connection 21... Vertical raised portion FIG, 2B

Claims (1)

Claims: 1) In a digital computer Eidirad process for fabricating a smooth, unfaceted reflector for a lighting device with a practical light dispersion pattern, said predetermined light pattern; Step (a) of digital computer input compared to digital
, (b) digitizing parameters of a plurality of shape functions specifying the surface of the reflector as input to a digital computer; (C) tracking a plurality of light paths projected onto a surface at a distance from said reflection 1gg; (d) determining a light intensity across said surface; recording said light intensity; Step (e) of comparing with a predetermined light pattern, the shape i
31) Step of changing the above parameters in 5),
By repeating the above steps (c) to (f), a light intensity that best matches the predetermined light pattern; A lighting device manufacturing method comprising the step of manufacturing. 2) determining the intersection of each ray with the surface of the reflector; determining the normal to the coordinates of the intersection;
Illumination according to claim 1, characterized in that the tracking step comprises the steps of projecting each ray path from said normal and determining the coordinates of the intersection of each ray path with said surface. Device manufacturing method. 3) The lighting device manufacturing method according to claim 1 or 2, wherein the step of counting the number of light rays intersecting each unit area of the surface is included in the light intensity determination step. . 4) The predetermined light pattern is designated as the minimum and maximum intensity at locations on the surface away from the headlights, and the result of counting the light paths intersecting each location is divided by the total number of light paths; A method for manufacturing a lighting device according to claim 1, characterized in that the comparing step includes a step of comparing the quotient with an intensity designated at a corresponding position. 5) The light intensity and the predetermined light intensity A patent, claim 1, further comprising the step of generating a performance function based on the results of the comparison with the light pattern, and optimizing the performance function by repeating each step of the process.
6) The digitally modeled light source includes a filament modeled as a hollow cylinder with temperature distribution in the longitudinal direction. 7) 7) A method of manufacturing a lighting device according to claim 1, characterized in that the digitally modeled light source includes a transparent envelope surrounding one or more filaments. 8) A method for manufacturing a lighting device according to claim 1 or claim 6. 8) Claim 7, wherein the transparent envelope is modeled as a glass cylinder with an opaque and a cap. 9) The method for manufacturing a lighting device according to claim 1, wherein the shape function includes a central deformed ellipsoid and two edge deformed ellipsoids. 10) the shape functions are digitally modeled surfaces, and the step of changing the parameters is adapted to the predetermined light pattern to create a smooth and continuous connection between the shape functions; 11. A method of manufacturing a lighting device according to claim 1 or claim 9, characterized in that the method includes modifying the digitally modeled shape function of: 11) changing the light rays reflected from the connection 11. A method of manufacturing a lighting device according to claim 10, characterized in that: 12) digitally modeling said shape function with smooth continuous connections in between; A method according to claim 1, characterized in that it further comprises the step of: tracing the light path of the illumination device according to claim 1. 1. The method of manufacturing a lighting device according to claim 2, further comprising the step of modeling distortions caused by distortion. Sealed beam reflector for automobile headlights manufactured by. 15) Sliding lamp for illumination device with practical light dispersion pattern and transparent front cover without flute and no facets carved. In a digital computer aided process for manufacturing a reflector, the step (a) of tinning the predetermined light pattern and transmitting it to a digital computer, the parameters of a plurality of shape functions specifying the surface of the reflector; (b) digitizing and providing input to said digital computer; (b) digitally modeled light source, intersecting said reflector, on a sphere surrounding said reflector; a step (C) of tracking a plurality of projected light paths; a step (e) of comparing dust traversing the surface of the sphere with the predetermined light pattern; and a step (e) of changing the parameters of the shape L[. f), step (g) of determining a shape function that produces a light intensity that best matches said predetermined light pattern by repeating steps (c) to (f); A method for manufacturing a lighting device, comprising a step (lj) of manufacturing a reflector. +6) An illumination device comprising a light source and a reflector for positioning the light source, the reflector having one or more smooth, continuous reflective surfaces that direct light from the light source in a desired direction. A lighting device characterized by providing direction in a pattern of. 17) The lighting device according to claim 10, characterized in that a transparent front cover without a flute is removed. 18) An illumination device according to claim 16 or 17, characterized in that it comprises a plurality of reflective surfaces connected in a smooth continuous articulation. 19) The reflective surface includes a medium-heat deformed ellipsoid and two enopane deformed ellipsoids, and directs light in the desired pattern between the edge ellipsoid and the central ellipsoid. Claim 16, characterized in that the circular surface is deformed by 5% to produce a smooth and continuous connection.
lj<:, bright device according to item or item 17. 20) The center of the central ellipsoid is modified to include a smooth vertical ridge, and the ellipsoid is inclined from the axis of the [[α light device. ≦The lighting device according to item 1. 2.7. %t of the edge ellipsoid is equal to 1 with the medium-heat ellipsoid (it has a vertically extending smooth connection, and the ellipsoid is concave), as claimed in claim 19. 22) A lighting device according to claim 16 or 17, characterized in that the reflective surface deflects light in a pattern adapted to a motor vehicle headlight, thereby forming a sealed beam motor vehicle headlight. The lighting device described in Section 1. 2;3)--The transparent front cover forms an aerodynamically desirable angle with respect to the headlights.Claim 22.i.
Moon headlight. 2/1) The illumination device according to claim 18, characterized in that the minimum radius of curvature of the connection between the reflected light beams m1 is greater than about 1.27 mm. 25) The illumination seat according to claim 24, wherein the minimum radius of curvature is greater than about 4.9 mm.