LED headlight architecture that creates a high quality beam pattern independent of LED shortcomings

One of the most challenging applications for high brightness LEDs is in automotive headlights. Optical designs for a low or high beam headlights are plagued by the low flux and luminance of LEDs compared to HID or incandescent sources, by mechanical chip placement tolerances and by color and flux variations between different LEDs. Furthermore the creation of a sharp cutoff is very difficult without baffles or other lossy devices. We present a novel LED headlight design that addresses all of the above problems by mixing the light of several LEDs first in a tailored light guide called LED combiner, thereby reducing color and flux variations between different LEDs and illuminance and color variations across the LED surfaces. The LED combiner forms a virtual source tailored to the 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. 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 (without cover lens) and performance as latest HID headlights have been achieved. Furthermore it is shown that the architecture has similar tolerance requirements as conventional mass produced headlights.