Etendue preserving mixing and projection optics for high brightness LEDs applied to automotive headlamps

A novel LED light extraction and mixing optic and two free form SMS surfaces are employed in a high efficiency projection optic. By combining the light of several high brightness LEDs with a single optical element, an ultrabright light source can be formed, whose shape and emission characteristics can be adapted to almost many kinds of illumination problems. A LED combiner forms a virtual source that is tailored for application. The illuminance distribution of this virtual source facilitates the generation of the desired intensity pattern by projecting it into the far field. The projection is accomplished by one refractive and one reflective freeform surface calculated by the 3D SMS method. The method is demonstrated for an LED automotive headlamp. A high quality intensity pattern shape and a very sharp cutoff are created tolerant to LED to optics misalignment and illuminance variations across the LED surface. A low and high beam design with more than 75% total optical efficiency have been achieved.