WO2015014062A1 - Led汽车前照灯及其自由曲面微透镜阵列 - Google Patents

Led汽车前照灯及其自由曲面微透镜阵列 Download PDF

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Publication number
WO2015014062A1
WO2015014062A1 PCT/CN2013/088721 CN2013088721W WO2015014062A1 WO 2015014062 A1 WO2015014062 A1 WO 2015014062A1 CN 2013088721 W CN2013088721 W CN 2013088721W WO 2015014062 A1 WO2015014062 A1 WO 2015014062A1
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WIPO (PCT)
Prior art keywords
free
light
illumination
form surface
led
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PCT/CN2013/088721
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English (en)
French (fr)
Inventor
王洪
陈赞吉
葛鹏
程露泉
Original Assignee
华南理工大学
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Priority claimed from CN201310330442.8A external-priority patent/CN103363444B/zh
Priority claimed from CN201310330109.7A external-priority patent/CN103363418B/zh
Application filed by 华南理工大学 filed Critical 华南理工大学
Publication of WO2015014062A1 publication Critical patent/WO2015014062A1/zh

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Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B3/00—Simple or compound lenses
    • G02B3/0006—Arrays
    • G02B3/0037—Arrays characterized by the distribution or form of lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/143—Light emitting diodes [LED] the main emission direction of the LED being parallel to the optical axis of the illuminating device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/10—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source
    • F21S41/14—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by the light source characterised by the type of light source
    • F21S41/141—Light emitting diodes [LED]
    • F21S41/147—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device
    • F21S41/148—Light emitting diodes [LED] the main emission direction of the LED being angled to the optical axis of the illuminating device the main emission direction of the LED being perpendicular to the optical axis
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25—Projection lenses
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/20—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by refractors, transparent cover plates, light guides or filters
    • F21S41/25—Projection lenses
    • F21S41/275—Lens surfaces, e.g. coatings or surface structures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
    • F21S41/00—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps
    • F21S41/30—Illuminating devices specially adapted for vehicle exteriors, e.g. headlamps characterised by reflectors
    • F21S41/32—Optical layout thereof
    • F21S41/321—Optical layout thereof the reflector being a surface of revolution or a planar surface, e.g. truncated
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B19/00—Condensers, e.g. light collectors or similar non-imaging optics
    • G02B19/0033—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use
    • G02B19/0047—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use for use with a light source
    • G02B19/0061—Condensers, e.g. light collectors or similar non-imaging optics characterised by the use for use with a light source the light source comprising a LED

Definitions

  • the present invention relates to the field of LED automotive headlamp illumination technology, and more particularly to LED automotive headlamps and free-form microlens arrays thereof. Background technique
  • LED light source is a new type of high-efficiency light source. According to research, LED has superior performance that cannot be replaced by other light sources, which can open up a huge application space for automotive headlamps. In particular, the LED light source has many advantages such as compactness, sturdiness, longevity, energy saving, planarization, and suitability for electromechanical integration, and satisfies people's requirements for safety, comfort, luxury, energy saving, environmental protection and versatility. These characteristics make LED light sources a hot spot for research and development at home and abroad.
  • the present invention is directed to the above problems, and provides an LED automobile headlamp and a free-form surface microlens array thereof.
  • the free-form optical microlens array combines light emitted by an LED chip to perform light distribution, and generates a light pattern. It can meet the national standard GB25991-2010 for the light distribution requirements of automotive LED headlamps, and does not require a light barrier.
  • the problem that the utilization rate of the projected LED headlamp is low in light energy is solved.
  • the invention adopts the following technical solutions:
  • Free-form microlens array for LED automotive headlamps, LED light from LED light source is collimated and then emitted as a parallel beam.
  • the free-form microlens array is arranged in a compact arrangement by a number of free-form microlenses. The entire cross section of the parallel beam is formed.
  • the incident surface of the free-form surface microlens is a plane, and the exit surface is a free curved surface.
  • the incident surface of the free-form surface microlens is a rectangular plane.
  • exit surface of the free-form surface microlens ie, the free-form surface
  • the light emitted by the LED light source is collimated and then emitted as a parallel beam.
  • a small rectangular area is selected in the cross section of the light beam.
  • the small rectangular area has a length of b and the illuminance in the minute rectangular area is regarded as an illuminance.
  • the light in the tiny rectangular area forms an illuminance spot on the illumination surface through the lens.
  • the table shows the illuminance value of the parallel beam in the tiny rectangular area, indicating the area of the micro-shaped area; the illuminance value of the spot on the illumination surface, indicating the area of the spot, is expressed as:
  • the area of the if 1 bright surface ( ⁇ ) is defined; the illuminance control factor is set according to the light distribution requirement of the LED automobile headlight to control the illuminance value of the designated area on the illumination surface to form the illuminance satisfying the requirement.
  • ⁇ . ⁇ indicates the illuminance value of G ( ) on the illumination surface, and the value of the illuminance is set according to the illuminance requirement on the illumination surface.
  • the larger the illuminance the larger the value of the area ⁇ , and the smaller the illuminance.
  • the smaller the value of the area ⁇ is; the energy of the jth line on the illumination surface is:
  • the micro-rectangular region of the outgoing parallel beam is meshed by the law of conservation of energy, and the micro-rectangular region is first divided into columns, corresponding to the energy distribution of the i-th column on the illumination surface, According to the law of conservation of energy, the energy of the i-th column of the tiny rectangular region is:
  • Pi is the width of the i-th column of the tiny rectangular region, and the Pi can be solved by combining the above formulas;
  • the micro-rectangular region is divided into rows, and according to the law of conservation of energy, the energy of the j-th row of the small rectangular region is:
  • the width of the jth row of the tiny rectangular region can be solved by combining the above formulas; Pi and q calculated by the two equations complete the meshing of the tiny rectangular region, and similarly, for each A small cell is numbered, and the i-th column of the j-th row is numbered ⁇ ); finally, the free-form surface of the micro-lens is calculated by the law of refraction according to the meshing of the illumination area and the small rectangular area of the beam section. Incident on the microlenses minute rectangular region with light rays, the illumination surface is formed g () with the inner surface of the illumination spot, the minute rectangular regions meet the lighting standard), respectively.
  • the free-form surface is set as the exit surface of the microlens, and a microlens having a plane of incidence is formed. Then, a plurality of such microlenses are arranged in an array, and the cross sections of the entire incident parallel beams are arranged and combined into one. Entity, you can get a free-form microlens array for LED automotive headlamps.
  • the invention also provides a headlight for LED automotive lighting, comprising an LED chip, an aluminum substrate and a heat sink, further comprising a collimator and the above-mentioned free-form microlens array, the LED chip is soldered on the aluminum substrate, the aluminum The substrate, the collimator and the free-form microlens array are mounted on the heat sink, and the light emitting surface of the LED chip faces the incident surface of the collimator, and the light passes through the collimator and exits in parallel beams, and is perpendicularly incident on the free-form microlens array. Incident surface.
  • the collimator employs a parabolic reflector.
  • the heat sink comprises a heat sink body and a fin structure disposed on the back surface of the heat sink body, and the LED light source is disposed on the main body of the heat sink through the aluminum substrate.
  • the parabolic reflector is made of an electroplated plastic material, and the inner surface of the reflector is a paraboloid to form an optical reflecting surface.
  • the present invention has the following advantages and technical effects:
  • the invention provides a free-form surface microlens array for LED automobile headlights.
  • the free-form optical microlens array performs light distribution after collimating the light emitted by the LED chip, and does not require a light blocking plate for light distribution, thereby reducing light distribution.
  • the system reduces the light energy utilization and improves the utilization of light energy.
  • the free-form optical design can effectively control the light direction and suppress the glare effect. At the same time, it can meet the national standard GB25991-2010 for the LED light headlights.
  • each of the microlenses of the free-form surface microlens array is independent, and can form a plurality of shapes of light spots, and has high design flexibility.
  • the headlight of the invention has few spare parts, simple and stable structure, convenient installation, high heat dissipation efficiency, and no need of light blocking plate for light distribution, reducing the loss of light energy of the light distribution system, and improving the utilization of light energy;
  • the curved optical design can effectively control the light direction, suppress the glare effect, and at the same time meet the light distribution requirements of the national standard GB25991-2010 for automotive LED headlamps, and each microlens of the free-form microlens array is independent. , and can form a variety of shapes of light spots, design flexibility.
  • FIG. 1 is a schematic diagram of a light distribution principle of an LED automobile headlight in an embodiment.
  • 2a is a schematic view of a parabolic reflecting collimator of an LED automobile headlamp in an embodiment
  • Figure 2b is a schematic illustration of a total reflection lens collimator for an LED automotive headlamp in an embodiment.
  • FIG. 3 is a schematic diagram of grid division of an illumination area of a low beam lamp in an embodiment.
  • FIG. 4 is a schematic diagram of mesh division of a small rectangular area in a parallel beam in the embodiment.
  • FIG. Fig. 5 is a schematic diagram showing the energy correspondence between the illumination area and the minute rectangular area in the embodiment.
  • Fig. 6 is a schematic view showing a microlens free curved surface in the embodiment.
  • 7a and 7b are respectively a three-dimensional schematic diagram of two different viewing angles of the microlens entity in the embodiment.
  • FIG. 8 is a three-dimensional schematic view of a free-form surface microlens array in an embodiment.
  • Fig. 9 is a structural exploded view of the LED automobile headlight in the embodiment.
  • FIG. 10 is a schematic diagram of the light distribution principle of the LED automobile headlight in the embodiment.
  • FIG. 11a is a schematic view showing the mounting of an LED chip, an aluminum substrate, and a heat sink in the embodiment
  • FIG. 1b is a schematic structural view of the aluminum substrate and the heat sink in the embodiment.
  • Figure 12 is a schematic view showing the mounting of the LED chip and the parabolic reflector in the embodiment.
  • 13a and 13b are schematic diagrams showing the installation structure of the whole lamp of two different viewing angles of the LED automobile headlamp in the embodiment.
  • DETAILED DESCRIPTION OF THE INVENTION The present invention will be further described in detail below in conjunction with the drawings and specific embodiments.
  • the light distribution principle of the free-form optical microlens array 100 for LED automotive headlamps provided by the present invention is shown in Fig. 1 (the arrows indicate the direction of the light beam). Since the national standard GB25991-2010 has the requirements for light distribution for the low beam and high beam of LED automotive headlamps, especially for the requirements of low beam, the specific embodiment is designed with low beam. The example is explained.
  • the light emitted by the LED light source is collimated.
  • the effect of collimation can be achieved by reflection or refraction.
  • the light is collimated and then emitted as a parallel beam.
  • the lighting area is meshed, as shown in Figure 3.
  • a non-equal illumination asymmetric spot is formed on the illumination surface.
  • the optical axis of the entire optical system is set to the z-axis, then the xoy plane is the illumination surface.
  • the illumination area is meshed, uniformly divided into m columns in the direction of the X-axis, and evenly divided into n rows in the direction of the y-axis, and each small cell is numbered, for example, the i-th column, the j-th row of the small cells The number is ( ⁇ .
  • the energy of the i-th column on the illumination surface is:
  • the above equation must satisfy: ⁇ m above, the average illuminance value of the illumination surface i 1 , indicating the area of the spot, indicating the area on the illumination surface; according to the national standard GB25991-2010, setting the illuminance control factor ) to control the designated area on the illumination surface
  • the illuminance value is used to form an illuminance distribution that satisfies the standard. E v .
  • fc (i ) represents the illuminance value on the illumination surface
  • the value of k (l ) needs to be set according to the illuminance requirement on the illumination surface, such as The larger the value of the area ⁇ where the illuminance is larger, the smaller the value of the area ⁇ where the illuminance is smaller.
  • the energy of the jth line on the illumination surface is:
  • n corresponding to the grid on the illumination surface, a small area of the incident parallel beam is meshed by the law of conservation of energy, which is set to be long for the convenience of calculation. For (for example, 8mm), a rectangle with a width of b (such as 4mm). The mesh division of the tiny rectangular region is completed according to the energy conservation relationship. For example, corresponding to the energy of the ith column on the illumination surface The quantity distribution, according to the law of conservation of energy, the energy of the i-th column of the tiny rectangular area is:
  • the micro-rectangular region is divided into rows, and according to the law of conservation of energy, the energy of the j-th row of the micro-rectangular region is:
  • the width of the jth row of the tiny rectangular region can be solved by combining the above equations.
  • the Pi sum calculated by these two equations can complete the meshing of the tiny rectangular area.
  • each cell is numbered, for example, the j-th row of the i-th column is numbered as g J> , as shown in FIG. 4 , where the dashed border is the range of the incident parallel beam.
  • the free surface of the microlens can be calculated by using the law of refraction, and the microlens distributes the light incident on the tiny rectangular area, so that the illumination surface forms a spot that satisfies the illumination standard.
  • the tiny rectangular area rt g ( ) corresponds to the illumination surface ( ⁇ ), as shown in FIG.
  • the iterative calculation it is first necessary to determine the starting point of a calculation, for example, starting from the center point of g (w) in the tiny rectangular region, g (u) corresponding to the illumination surface G (u) , passing through the center point.
  • the coordinates of the coordinates and the coordinates of the G( u ) center point can be used to obtain the direction vector of the outgoing ray.
  • the normal vector of the center point can be obtained by using the law of refraction to determine the tangent plane of the point, the tangential plane and the ray incident on the center point.
  • the coordinates of the calculated point and the coordinates of the u ) center point can be used to obtain the direction vector of the next outgoing ray, and then the above-mentioned calculation method is used to find the tangent plane of the point and the next calculation point.
  • the coordinates of all the calculated points can be obtained by computer iteration, and the series of calculated points can be fitted into the free-form surface 1011 of the microlens, and the free-form surface 101 1 is set as the microlens as shown in FIG.
  • the exit surface is formed into a microlens 101 whose entrance surface is a plane 1012, as shown in Figs. 7a and 7b.
  • a free-form microlens array 100 for LED automotive headlamps is available, as shown in FIG.
  • the free-form microlens array for LED automotive headlamps provided by the present invention is described in detail above.
  • the free-form optical microlens array aligns the light emitted by the LED chip, and does not require a light blocking plate for light distribution.
  • the light distribution system reduces the loss of light energy, improves the utilization of light energy, and has good light distribution performance.
  • the free-form optical design can effectively control the light direction and suppress the glare effect, and at the same time meet the national standard GB25991-2010.
  • the microlens array type headlamp for LED automotive illumination is composed of an LED chip 109, an aluminum substrate 200, a heat sink 300, a parabolic reflector 400, and a free-form microlens array 100.
  • the LED chip is soldered to a fixed position on the aluminum substrate, and the aluminum substrate, the parabolic reflector, and the free-form microlens array are mounted on the heat sink by corresponding mounting means.
  • the light distribution principle of the microlens array type headlamp for LED automobile illumination provided by the present invention is as shown in FIG. 10, the headlight does not need a light blocking plate, and the optical system only includes the LED chip 109, the parabolic reflector 400 and the free curved surface micro Lens array 100.
  • the parabolic reflector is made of an electroplated plastic material.
  • the inner surface of the reflector is a paraboloid that forms an optically reflective surface.
  • the function of the parabolic reflector is to collimate the light emitted by the LED chip, so that the light is reflected by the parabolic reflector and then emitted as a parallel beam.
  • the free-form optical microlens array is made of optically transparent material, and the free-form optical microlens array re-aligns the light collimated by the parabolic reflector to produce a light pattern that meets national standards.
  • the heat sink 300 includes a heat sink body and a fin structure disposed on the back surface of the heat sink body, and the LED chip 109 is disposed on the heat sink body through the aluminum substrate 200, and passes through
  • the fin structure on the back of the heat sink body conducts heat generated by the operation of the LED light source and is emitted into the air, as shown in FIG. 11a and FIG.
  • Good heat dissipation conditions ensure that the LED light source can work under normal ambient temperature, combined with the optimized design of the secondary optical components to make the LED motorcycle headlights meet the light distribution performance requirements.
  • the heat is released in time, which will not lead to the change and attenuation of the performance of the LED chip, improve the service life of the lamp, and ensure the safety of driving.
  • the parabolic reflector 400 and the free-form microlens array 500 are mounted on the heat sink 300 by a corresponding assembly manner, wherein the focus of the parabolic reflector is located at the center of the light emitting surface of the LED chip 109, as shown in FIG. 12, the free-form surface microlens
  • the incident plane of the array is perpendicular to the parallel beam that is reflected by the parabolic reflector, as shown in Figures 13a and 13b.
  • the microlens array type headlamp for LED automotive lighting provided by the present invention is described in detail above.
  • the LED automobile headlamp has few spare parts, simple and stable structure, is easy to install, has high heat dissipation efficiency, and does not require a light blocking plate.
  • Light distribution reducing the loss of light energy in the light distribution system, improving the utilization of light energy;
  • Using the free-form optical design it can effectively control the light direction, suppress the glare effect, and at the same time meet the national standard GB25991-2010 for automotive LED
  • the light distribution requirements of the headlights, and each of the microlenses of the free-form microlens array are independent, and can form a variety of shapes of light spots, and the design flexibility is high.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Optics & Photonics (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • General Physics & Mathematics (AREA)
  • Non-Portable Lighting Devices Or Systems Thereof (AREA)

Abstract

一种LED汽车前照灯及其自由曲面微透镜阵列（100）,自由曲面微透镜阵列（100）由若干个自由曲面微透镜紧凑排列布满整个平行光束的截面构成；所有自由曲面微透镜为一体形成；自由曲面微透镜的入射面为平面（1012）,出射面为自由曲面（1011）。前照灯包括LED芯片（109）、铝基板（200）和散热器（300），还包括准直器（400）和自由曲面微透镜阵列（100）。不需要挡光板进行配光，减少了配光系统对光能的损耗，提高了光能利用率；采用自由曲面光学设计，可以有效控制光线走向，抑制眩光效应；前照灯结构简单、散热效率高，同时又能达到国家标准GB25991-2010对汽车用LED前照灯的配光要求。

Description

LED汽车前照灯及其自由曲面微透镜阵列 技术领域 本发明涉及 LED汽车前照灯照明技术领域，特别涉及 LED汽车 前照灯及其自由曲面微透镜阵列。 背景技术
LED光源是一种新型高效光源， 根据研究表明， LED具有其它 光源不能替代的优越性能， 可为汽车前照灯开辟巨大的应用空间。尤 其是 LED光源具有小巧、 坚固、 长寿、 节能、 平面化、 适合机电一 体智能化等诸多优点， 满足了人们对汽车前照灯安全、 舒适、 豪华、 节能、 环保与多功能等方面的要求。 这些特点使得 LED光源成为目 前国内外竞相研发的一个热点。
由于 LED相比于其他光源， 发光特性有很大的差别， 芯片阵列 的排布和灯具结构的设计都会影响到最终效果， 使 LED光源应用于 摩托车前照灯时要面临更加复杂的光学设计问题。 目前， 使用得比较 广泛的是投射式 LED前照灯设计， 这种光学设计可以形成很好的光 型效果， 但在近光灯设计时还需加上挡光板， 整个光学系统复杂， 光 能利用率较低。 发明内容 本发明针对上述存在的问题，提供了 LED汽车前照灯及其自由曲 面微透镜阵列， 该自由曲面光学微透镜阵列将 LED芯片发出的光经 过准直后进行配光， 产生的光型能满足国家标准 GB25991-2010对汽 车用 LED前照灯的配光要求， 而且不需要挡光板， 解决了投射式 LED前照灯设计光能利用率较低的问题。 本发明采用 如下技术方案：
LED 汽车前照灯用的自由曲面微透镜阵列， LED 汽车前照灯中 LED光源发出的光经过准直后以平行光束射出， 所述自由曲面微透镜 阵列由若干个自由曲面微透镜紧凑排列布满整个所述平行光束的截 面构成。
进一步改进的， 所有自由曲面微透镜为一体形成。
进一步改进的， 所述自由曲面微透镜的入射面为平面， 出射面为 自由曲面。
进一步改进的， 所述自由曲面微透镜的入射面为矩形平面。
进一步改进的，所述自由曲面微透镜的出射面即自由曲面确定如 下：
LED光源发出的光经过准直后以平行光束射出， 在该光束的截面 内选取一个微小矩形区域， 该微小矩形区域长为^ 宽为 b， 该微小 矩形区域内的照度视为等照度，该微小矩形区内的光经过透镜在照明 面上形成一个等照度的光斑， 根据能量守恒定律有：
E0 - S0 = Ev - Sv ，
E。表示出射平行光束在微小矩形区内的照度值， 表示该微小矩 形区的面积； 表示照明面上光斑的照度值， 表示该光斑的面积， 则 表示为：
Ev = E0 ' t ，
式中 为微小矩形区域的面积 S0与光斑的面积 的比值； 然后， 依据对 LED汽车前照灯的配光要求， 照明面上要形成一个 非等照度的光斑， 令整个 LED汽车前照灯的光轴为 z轴， 那么 xoy 平面为照明面， 对照明区域进行网格划分， 即在 X轴的方向上均匀划 分成 m列， 在 y轴的方向上均匀划分成 n行， 对每一小格进行编号， 其中第 i列第 j行小格 编号为 G( )， 则照明面上第 i列的能量为： 同时， 上述等式要满足: m
Ev-Sv =∑Q(lfi) ，
上面两式中， 表示 if1明面上 (^)的面积； 根据 LED汽车前照 灯的配光要求设置照度控制因子 来控制照明面上指定区域的照度 值大小， 用以形成满足要求的照度分布， 则^.^^表示照明面上 G( ) 的照度值， 的取值大小根据照明面上照度要求进行设定， 对于照 度越大的区域 ^的取值越大， 对于照度越小的区域 ^的取值越小; 照明面上第 j行的能量为：
m 同时， 上述等式要满 n n
d ∑2(。 ，
然后对应于照明面上的^¾划分，通过能量守恒定律对出射平行 光束的微小矩形区域进行网格划分，首先对该微小矩形区域进行列划 分， 对应于照明面上第 i列的能量分布， 根据能量守恒定律， 该微小 矩形区域第 i列的能量为：
E0 'b'Pi =Q( ，
式中， Pi为该微小矩形区域第 i列的宽度， 联合上述几式可求解 出 Pi；
同理， 对该微小矩形区域进行行划分， 根据能量守恒定律， 该矩 形小区域第 j行的能量为：
E0 -a-qj =Q(0 ) ，
式中， 为该微小矩形区域第 j行的宽度， 联合上述几式可求解 出 ； 由这两个等式计算得到的 Pi和 q]完成该微小矩形区域的网格划 分， 同样的，对每一小格进行编号，第 i列第 j行小格的编号为^ ); 最后， 根据照明区域和光束截面微小矩形区域的网格划分， 利用 折射定律计算微透镜的自由曲面。微透镜对入射到微小矩形区域的光 线进行配光， 使照明面上形成满足照明标准的光斑， 微小矩形区域内 g( )与照明面上 ,)相对应。 将该自由曲面设为微透镜的出射面，做成一个入射面为平面的微 透镜， 再对若干个这样的微透镜进行阵列排布， 排列布满整个入射平 行光束的截面， 并组合成一个实体， 即可得到 LED汽车前照灯用的 自由曲面微透镜阵列。
本发明还提供了一种 LED汽车照明用的前照灯， 包括 LED芯片、 铝基板和散热器，其还包括准直器和上述的自由曲面微透镜阵列， LED 芯片焊接在铝基板上， 铝基板、准直器和自由曲面微透镜阵列安装于 散热器上， LED芯片的发光面朝向准直器的入射面， 光线经准直器后 以平行光束出射， 并垂直入射自由曲面微透镜阵列的入射面。
进一步改进的， 所述准直器采用抛物面反射器。
进一步改进的，所述散热器包括散热器主体和布设于散热器主体 背面的鳍片式结构， LED光源通过铝基板安置于该散热器的主体上。
进一步改进的， 所述抛物面反射器由电镀塑胶材料制成， 反射器 的内表面是抛物面， 构成光学反射面。
与现有技术相比， 本发明具有如下优点和技术效果：
本发明提供了 LED汽车前照灯用的自由曲面微透镜阵列， 该自 由曲面光学微透镜阵列将 LED芯片发出的光经过准直后进行配光， 不需要挡光板进行配光， 减少了配光系统对光能的损耗， 提高了光能 利用率； 采用自由曲面光学设计， 可以有效控制光线走向， 抑制眩光 效应， 同时又能达到国家标准 GB25991-2010对汽车用 LED前照灯 的配光要求， 而且自由曲面微透镜阵列的每一个微透镜都是独立的， 而且能形成多种形状的光斑， 设计灵活性高。
本发明的前照灯零配件少、 结构简单稳定、 便于安装、 散热效率 高、 而且不需要挡光板进行配光， 减少了配光系统对光能的损耗， 提 高了光能利用率； 采用自由曲面光学设计， 可以有效控制光线走向， 抑制眩光效应， 同时又能达到国家标准 GB25991-2010对汽车用 LED 前照灯的配光要求，而且自由曲面微透镜阵列的每一个微透镜都是独 立的， 而且能形成多种形状的光斑， 设计灵活性高。 附图说明 图 1为实施方式中 LED汽车前照灯的配光原理示意图。
图 2a为实施方式中 LED汽车前照灯的抛物面反射准直器示意 图；
图 2b为实施方式中 LED汽车前照灯的全反射透镜准直器示意 图。
图 3为实施方式中近光灯的照明区域网格划分示意图。
图 4为实施方式中平行光束内的微小矩形区域网格划分示意图。 图 5为实施方式中照明区域和微小矩形区域的能量对应示意图。 图 6为实施方式中微透镜自由曲面的示意图。
图 7a、 图 7b分别为实施方式中微透镜实体的两种不同视角的三 维示意图。
图 8为实施方式中自由曲面微透镜阵列的三维示意图。
图 9为实施方式中 LED汽车前照灯的结构爆炸图。
图 10为实施方式中 LED汽车前照灯的配光原理示意图。
图 11a为实施方式中 LED芯片、铝基板和散热器的安装示意图； 图 lib为实施方式中铝基板和散热器的结构示意图。
图 12为实施方式中 LED芯片和抛物面反射器的安装示意图。 图 13a、图 13b为实施方式中 LED汽车前照灯的两种不同视角的 整灯安装结构示意图。 具体实施方式 下面结合附图和具体实施方式对本发明作进一步详细的说明。 本发明提供的 LED汽车前照灯用的自由曲面光学微透镜阵列 100配光原理如图 1所示 （图中箭头表示光束的方向）。 由于国家标 准 GB25991-2010对 LED汽车前照灯的近光和远光都进行了配光要 求， 特别对近光的要求比较严苛， 则该具体实施方式以近光的设计为 例进行说明。
首先， LED光源发出的光要进行准直处理， 准直的效果可以通过 反射或者折射等方式达到， 如图 2a、 图 2b所示， 光线经过准直后以 平行光束射出。
然后， 对照明区域进行网格划分， 如图 3所示。 依据国家标准 GB25991-2010对 LED汽车前照灯近光的配光要求， 照明面上要形成 一个非等照度的不对称光斑。先设定整个光学系统的光轴为 z轴， 那 么 xoy平面为照明面。对照明区域进行网格划分， 在 X轴的方向上均 匀划分成 m列， 在 y轴的方向上均匀划分成 n行， 对每一小格进行编 号， 例如第 i列第 j行小格的编号为(^。 当然， 网格划分得越小， 即 m和 n的数值越大，计算的 ^度会越高。照明面上第 i列的能量为： 同时， 上述等式要满足： ^ m 上面两式中， 表示照明面上光 i1的平均照度值， 表示该光斑 的面积， 表示照明面上 的面积；根据国家标准 GB25991-2010, 设置照度控制因子 )来控制照明面上指定区域的照度值大小， 用以 形成满足标准的照度分布，则 Ev . fc(i )表示照明面上 的照度值， k(l ) 的取值大小需根据照明面上照度要求进行设定，如对于照度越大的区 域 ^的取值越大， 对于照度越小的区域 ^的取值越小。
同理， 照明面上第 j行的能量为：
m 同时， 上述等式要满足： n 接着， 对应于照明面上的网格划 ， 通过能量守恒定律对入射平 行光束的一个小区域进行网格划分， 为了方便计算， 该小区域设定为 长为 （如 8mm)， 宽为 b (如 4mm) 的矩形。 根据能量守恒关系计算 完成该微小矩形区域的网格划分。例如， 对应于照明面上第 i列的能 量分布， 根据能量守恒定律， 该微小矩形区域第 i列的能量为：
E0 - b - Pi = Q(
式中， E。表示出射平行光束某一小区域内的照度值， A为该微小 矩形区域第 i列的宽度， 联合上述几式可求解出 A。
同理， 对该微小矩形区域进行行划分， 根据能量守恒定律， 该微 小矩形区域第 j行的能量为：
Figure imgf000009_0001
式中， 为该微小矩形区域第 j行的宽度， 联合上述几式可求解 出 。由这两个等式计算得到的 Pi和 可以完成该微小矩形区域的网 格划分。 同样的， 对每一小格进行编号， 例如第 i列第 j行小格的编 号为 g J> , 如图 4所示， 其中虚线边框为入射平行光束的范围。
最后， 根据照明区域和微小矩形区域的网格划分， 可以利用折射 定律计算微透镜的自由曲面，微透镜对入射到微小矩形区域的光线进 行配光， 使照明面上形成满足照明标准的光斑， 微小矩形区域 rt g( ) 与照明面上 (^ )相对应， 如图 5所示。
在迭代计算时， 首先需要确定一个计算的起始点， 例如， 以微小 矩形区域内 g(w)的中心点为起始点， g(u)对应着照明面上 G(u)， 通过 中心点的坐标和 G(u)中心点的坐标可以得到出射光线的方向向 量， 利用折射定律计算可以得出 中心点的法向向量， 从而确定该 点的切平面， 该切平面与入射到 中心点的光线相交从而确定下一 个计算点，通过这个计算点的坐标和 u)中心点的坐标可以得到下一 个出射光线的方向向量，再通过上述的计算方法求出该点的切平面和 再下一个计算点， 以此类推， 通过计算机迭代可得出所有计算点的坐 标， 由这一系列计算点可拟合成微透镜的自由曲面 101 1， 如图 6所 将该自由曲面 101 1设为微透镜的出射面， 做成一个入射面为平 面 1012的微透镜 101， 如图 7a、 图 7b所示。对该微透镜进行阵列排 布， 排列布满整个入射平行光束的截面， 并组合成一个实体模型， 即 可得到 LED汽车前照灯用的自由曲面微透镜阵列 100， 如图 8所示。 以上对本发明所提供的 LED汽车前照灯用自由曲面微透镜阵列 进行了详细介绍， 该自由曲面光学微透镜阵列将 LED芯片发出的光 经过准直后进行配光， 不需要挡光板进行配光， 减少了配光系统对光 能的损耗，提高了光能利用率，配光性能好；采用自由曲面光学设计， 可以有效控制光线走向， 抑制眩光效应， 同时又能达到国家标准 GB25991-2010对汽车用 LED前照灯的配光要求，而且自由曲面微透 镜阵列的每一个微透镜都是独立的， 而且能形成多种形状的光斑， 设 计灵活性高。 本发明中应用了各种模型图对具体实施方式进行了阐 述， 以上所述仅为本发明较佳可行的实施例子而已。对于本领域的技 术人员， 依据本发明的思想， 在具体实施方式及应用范围上均会有改 善之处。 综上所述， 本说明书内容不应理解为对本发明的限制。
如图 9所示， 本发明提供的 LED汽车照明用的微透镜阵列型前 照灯是由 LED芯片 109、铝基板 200、散热器 300、抛物面反射器 400 和自由曲面微透镜阵列 100组成的。 LED芯片焊接在铝基板固定的 位置上， 铝基板、抛物面反射器和自由曲面微透镜阵列通过相应的装 配方式安装于散热器上。
本发明提供的 LED汽车照明用的微透镜阵列型前照灯配光原理 如图 10所示， 该前照灯不需要挡光板， 光学系统仅包括 LED芯片 109、 抛物面反射器 400和自由曲面微透镜阵列 100。 抛物面反射器 由电镀塑胶材料制成， 反射器的内表面是抛物面， 构成光学反射面。 抛物面反射器的作用是将 LED芯片发出的光进行准直配光， 使光线 经过抛物面反射器反射后以平行光束射出。自由曲面光学微透镜阵列 由光学透明材料制成， 自由曲面光学微透镜阵列将经过抛物面反射器 准直后的光再次进行配光， 产生的光型能满足国家标准
GB25991-2010对汽车用 LED前照灯的配光要求。
散热器 300 包括散热器主体和布设于散热器主体背面的鳍片式 结构， LED芯片 109通过铝基板 200安置于该散热器主体上， 通过 散热器主体背面的鳍片式结构将 LED光源工作时产生的热量传导并 散发到空气中， 如图 lla、 图 lib所示。 良好的散热条件保证了 LED 光源能在正常环境温度工作的基础上，结合二次光学部件的优化设计 使 LED摩托车前照灯达到配光性能要求。 同时， 热量的及时散发出 去， 才不会导致 LED芯片性能的变化与衰减， 提高车灯的使用寿命， 保障了驾驶的安全性。
抛物面反射器 400和自由曲面微透镜阵列 500通过相应的装配方 式安装于散热器 300上， 其中， 抛物面反射器的焦点位于 LED芯片 109发光面的中心处， 如图 12所示， 自由曲面微透镜阵列的入射平 面垂直于经抛物面反射器反射后射出的平行光束， 如图 13a、 图 13b 所示。
以上对本发明所提供的 LED汽车照明用的微透镜阵列型前照灯 进行了详细介绍， 该 LED汽车前照灯零配件少、 结构简单稳定、 便 于安装、 散热效率高、 而且不需要挡光板进行配光， 减少了配光系统 对光能的损耗， 提高了光能利用率； 采用自由曲面光学设计， 可以有 效控制光线走向， 抑制眩光效应， 同时又能达到国家标准 GB25991-2010对汽车用 LED前照灯的配光要求，而且自由曲面微透 镜阵列的每一个微透镜都是独立的， 而且能形成多种形状的光斑， 设 计灵活性高。 本发明中应用了各种模型图对具体实施方式进行了阐 述， 以上所述仅为本发明较佳可行的实施例子而已。对于本领域的技 术人员， 依据本发明的思想， 在具体实施方式及应用范围上均会有改 善之处。 综上所述， 本说明书内容不应理解为对本发明的限制。

Claims

权 利 要 求 书
1、 LED汽车前照灯用的自由曲面微透镜阵列， LED汽车前照灯中 LED 光源发出的光经过准直后以平行光束射出， 其特征在于， 所述自由曲 面微透镜阵列由若干个自由曲面微透镜紧凑排列布满整个所述平行 光束的截面构成。
2、 根据权利要求 1所述的自由曲面微透镜阵列， 其特征在于所有自 由曲面微透镜为一体形成。
3、 根据权利要求 1所述的自由曲面微透镜阵列， 其特征在于所述自 由曲面微透镜的入射面为平面， 出射面为自由曲面。
4、 根据权利要求 3所述的自由曲面微透镜阵列， 其特征在于所述自 由曲面微透镜的入射面为矩形平面。
5、 根据权利要求 4所述的自由曲面微透镜阵列， 其特征在于所述自 由曲面微透镜的出射面即自由曲面确定如下：
LED光源发出的光经过准直后以平行光束射出， 在该光束的截面 内选取一个微小矩形区域， 该微小矩形区域长为^ 宽为 b， 该微小 矩形区域内的照度视为等照度，该微小矩形区内的光经过透镜在照明 面上形成一个等照度的光斑， 根据能量守恒定律有：
E0 - S0 = EV - SV ，
E。表示出射平行光束在微小矩形区内的照度值， 表示该微小矩 形区的面积； 表示照明面上光斑的照度值， 表示该光斑的面积， 则 表示为：
Ev = E0 - t ，
式中 为微小矩形区域的面积 S0与光斑的面积 的比值； 然后， 依据对 LED汽车前照灯的配光要求， 照明面上要形成一个 非等照度的光斑， 令整个 LED汽车前照灯的光轴为 z轴， 那么 xoy 平面为照明面， 对照明区域进行网格划分， 即在 X轴的方向上均匀划 分成 m列， 在 y轴的方向上均匀划分成 n行， 对每一小格进行编号， 其中第 i列第 j行小格 编号为 G( )， 则照明面上第 i列的能量为： 同时， 上述等式要满足: ^
EV-SV =∑Q(,0) ，
上面两式中， S( )表示 if1明面上 (^)的面积； 根据 LED汽车前照 灯的配光要求设置照度控制因子 来控制照明面上指定区域的照度 值大小， 用以形成满足要求的照度分布， 则 . ^表示照明面上 G( ) 的照度值， 的取值大小根据照明面上照度要求进行设定， 对于照 度越大的区域 ^的取值越大， 对于照度越小的区域 的取值越小; 照明面上第 j行的能量为：
m 同时， 上述等式要满 η
d ∑2(。 ，
然后对应于照明面上的^¾划分，通过能量守恒定律对出射平行 光束的微小矩形区域进行网格划分，首先对该微小矩形区域进行列划 分， 对应于照明面上第 i列的能量分布， 根据能量守恒定律， 该微小 矩形区域第 i列的能量为：
E0 -b-Pi =Q( ，
式中， A为该微小矩形区域第 i列的宽度， 联合上述几式可求解 出 Pi；
同理， 对该微小矩形区域进行行划分， 根据能量守恒定律， 该矩 形小区域第 j行的能量为：
E0■a-qj =Q(0 ) ，
式中， 为该微小矩形区域第 j行的宽度， 联合上述几式可求解 出 ；由这两个等式计算得到的 Pi和 完成该微小矩形区域的网格划 分， 同样的，对每一小格进行编号，第 i列第 j行小格的编号为^ ); 最后， 根据照明区域和光束截面微小矩形区域的网格划分， 利用 折射定律计算微透镜的自由曲面。
6、 LED汽车照明用的前照灯，包括 LED芯片、铝基板和散热器， 其特征在于还包括准直器和权利要求 1〜5任一项所述的自由曲面微 透镜阵列， LED 芯片焊接在铝基板上， 铝基板、 准直器和自由曲面 微透镜阵列安装于散热器上， LED 芯片的发光面朝向准直器的入射 面， 光线经准直器后以平行光束出射， 并垂直入射自由曲面微透镜阵 列的入射面。
7、 根据权利要求 6所述的前照灯， 其特征在于所述准直器采用 抛物面反射器。
8、 根据权利要求 6所述的前照灯， 其特征在于所述散热器包括 散热器主体和布设于散热器主体背面的鳍片式结构， LED光源通过 铝基板安置于该散热器的主体上。
9、 根据权利要求 6所述的前照灯， 其特征在于所述抛物面反射 器由电镀塑胶材料制成，反射器的内表面是抛物面，构成光学反射面。
PCT/CN2013/088721 2013-07-31 2013-12-06 Led汽车前照灯及其自由曲面微透镜阵列 WO2015014062A1 (zh)

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