JP7797773B2 - Multi-color lighting devices, systems and methods of manufacture - Google Patents

Description

This application claims the benefit of U.S. Non-Provisional Patent Application No. 16/999,577, filed August 21, 2020, and European Patent Application No. 20193561.6, filed August 31, 2020, the contents of which are incorporated herein by reference.

The present invention relates to the field of multi-color lighting devices, systems, and manufacturing methods.

Lighting devices based on light-emitting diodes (LEDs) can offer advantages in terms of light output and energy efficiency and therefore could be a welcome alternative to traditional light sources such as filament lamps in automotive applications.

The lighting device includes an electrical insulating layer. The electrical insulating layer has a top surface and a metallized bottom surface and has a thermal conductivity greater than 10 W/(m*K). The lighting device also includes at least one first light-emitting element located on the top surface of the electrical insulating layer and configured to emit light of a first color, and at least one second light-emitting element located on the top surface of the electrical insulating layer and configured to emit light of a second color. At least one electrical contact element is disposed on at least a portion of the top surface of the electrical insulating layer and is electrically coupled to at least one of the at least one first light-emitting element or the at least one second light-emitting element.

A more detailed understanding can be had from the following description, taken by way of example in conjunction with the accompanying drawings.

FIG. 1 is a perspective view of an exemplary lighting device. FIG. 1B is a circuit diagram of an exemplary circuit for electrically connecting the lighting device of FIG. 1A. FIG. 1C is the circuit diagram of FIG. 1B with the direction of current flow reversed. FIG. 2 is a perspective view of the lighting device. 2B is a circuit diagram of an exemplary circuit for electrically connecting the lighting device of FIG. 2A. 1A or 2A may be incorporated into an exemplary vehicle headlamp system. FIG. 2 is a diagram of another exemplary vehicle headlamp system. 2B is a flow diagram of a method for manufacturing an illumination device such as the illumination device of FIG. 1A or 2A.

Examples of different optical illumination systems and/or light emitting diode ("LED") implementations are described in more detail herein with reference to the accompanying drawings. These examples are not mutually exclusive, and features found in one example may be combined with features found in one or more other examples to achieve additional implementations. Accordingly, it is understood that the examples shown in the accompanying drawings are provided for illustrative purposes only and are not intended to limit the present disclosure in any way. Like numbers refer to like elements throughout.

Terms such as first, second, and third may be used herein to describe various elements, but it is understood that the elements should not be limited by these terms. These terms may be used to distinguish one element from another. For example, a first element may be referred to as a second element and a second element may be referred to as the first element without departing from the scope of the present invention. As used herein, the term "and/or" may include any and all combinations of one or more of the associated listed items.

When an element, such as a layer, region, or substrate, is referred to as being "on" or "extending onto" another element, it is understood that it may be directly on or extending onto the other element, or that intervening elements may also be present. In contrast, when an element is referred to as being "directly on" or extending "directly onto" another element, there may not be intervening elements. Also, when an element is referred to as being "connected" or "coupled" to another element, it is understood that the element may be directly connected or coupled to the other element and/or may be connected or coupled to the other element via one or more intervening elements. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements between the element and the other element. It is understood that these terms are intended to encompass different orientations of the elements in addition to any orientations depicted in the figures.

Relative terms such as "below," "above," "up," "below," "horizontal," or "vertical" may be used herein to describe the relationship of an element, layer, or region to another element, layer, or region, as shown in the figures. It is understood that these terms are intended to encompass different orientations of the device in addition to the orientation shown in the figures.

While offering such advantages in terms of light output energy and efficiency, the use of LEDs also presents many challenges. For example, LEDs can be difficult to precisely align with complementary optics (such as reflectors and light guides), and thermal management can be challenging. Furthermore, LED-based automotive lighting systems, such as daytime running lights and turn signals, can rely on customized and complex solutions, preventing their availability in mass production.

The embodiments described herein may enable improved thermal management, provide lighting devices that can be used with existing complementary optical systems, and support reduced overall system complexity. The embodiments described herein may additionally or alternatively provide corresponding automotive lighting systems and methods of manufacturing lighting devices.

1A is a perspective view of an exemplary lighting device 100. In the example of FIG. 1A, the lighting device 100 includes an interface layer 101 and an electrical insulating layer 103 disposed on the interface layer 101. The lighting device 100 may further include a mounting portion 110 that includes respective portions of the interface layer 101 and the electrical insulating layer 103. A first light-emitting element 111 and a second light-emitting element 113 may be mounted to the mounting portion 110, thereby allowing their respective positions within the lighting device 100 to be mechanically adjusted. A gap 112 may be provided between the first light-emitting element 111 and the second light-emitting element 113.

By providing at least one first light-emitting element and at least one second light-emitting element on an electrical insulating layer, a compact and stable construction can be achieved. The electrical insulating layer may function as a support structure for the at least one first light-emitting element and/or the at least one second light-emitting element, and may therefore be considered the backbone of the lighting device. Furthermore, by providing the at least one first light-emitting element and at least one second light-emitting element on an electrical insulating layer, they may in turn be disposed on an interface layer, which may provide a path for heat generated by the light-emitting elements to be dissipated via the interface layer. Therefore, the specific arrangement of these components may enable beneficial thermal management.

To facilitate favorable heat transport, in embodiments, the interface layer may be thermally conductive. For example, the thermal conductivity of the interface layer may be greater than 100 W/(m*K) in embodiments. Suitable thermal conductivity can be achieved by appropriate selection of the interface layer material. In embodiments, the interface layer may include or be a metal such as aluminum (Al), copper (Cu), and/or gold (Au). In some embodiments, the interface layer includes or is gold-coated copper.

In embodiments, the interface layer may be in direct mechanical contact with the electrical insulation layer. In this manner, thermal coupling between the interface layer and the electrical insulation layer is achieved, and heat generated by the at least one first light-emitting element and the at least one second light-emitting element disposed on the insulation layer may be advantageously guided away through the interface layer, thereby improving thermal management of the lighting device. In embodiments, the thickness of the electrical insulation layer may be 0.5 mm or less, 0.4 mm or less, and/or 0.3 mm or less. Such thin electrical insulation layers may be particularly beneficial for improving heat transport through the electrical insulation layer. In embodiments, the interface layer may correspond to or include a plate or substrate that allows for improved coupling between this structure and the electrical insulation layer. In embodiments, the interface layer may further be coupled to a heat sink to direct heat away from the lighting device.

In embodiments, the interface layer may be an interface plate, such as one that includes or consists essentially of a metal. In embodiments, the metal may have a thermal conductivity of 100 W/(m*K) or greater, such as greater than 300 W/(m*K).

In embodiments, the electrical insulation layer may be in direct mechanical contact with the interface plate. As previously discussed, direct mechanical contact between the electrical insulation layer and the interface layer allows for advantageous thermal coupling of these components and further allows for advantageous dissipation of heat generated by the at least one first and at least one second light-emitting element.

The electrical insulation layer may be formed of any suitable material, such as a suitable plastic material. However, ceramic materials may be particularly advantageous. In embodiments, the electrical insulation layer may include a ceramic material and/or a material with a thermal conductivity greater than 10 W/(m*K) or greater than 100 W/(m*K). In embodiments, the electrical insulation layer may include or be aluminum nitride (AlN). In this manner, suitable mechanical rigidity and reliability may be achieved using a material with high thermal conductivity. In embodiments, the electrical insulation layer and/or the lighting device may not include an insulated metal substrate (IMS).

Furthermore, the electrical insulation layer 103 may include a support portion 103a and a covering portion 103b. The support portion 103a may advantageously provide overall mechanical stability for the lighting device 100, while the covering portion 103b may protect the first light-emitting element 111 and the second light-emitting element 113 from environmental conditions such as dust and humidity, and may enhance heat dissipation by increasing the contact area between the first and second light-emitting elements 111, 113 and the electrical insulation layer 103.

In embodiments, at least one first light-emitting element and/or at least one second light-emitting element may correspond to or include a light-emitting diode (LED). In embodiments, at least one first light-emitting element and/or at least one second light-emitting element may correspond to or include one or more LED dies. In other words, although the light-emitting element may include additional components, the light emitted by the light-emitting element may be generated by an LED. LEDs are particularly advantageous in terms of energy efficiency, and in that LEDs can be realized in different shapes and colors depending on the desired application.

The at least one first light-emitting element and the at least one second light-emitting element can be configured to emit light of a first color and a second color, respectively. According to some embodiments, at least one of the at least one first light-emitting element and the at least one second light-emitting element can further include a respective phosphor layer disposed on a corresponding light output surface of each of the at least one first light-emitting element and the at least one second light-emitting element. By appropriately selecting the phosphor coating, the color of light emitted from the corresponding light-emitting element can be appropriately adjusted. Alternatively, in some embodiments, the at least one first light-emitting element and the at least one second light-emitting element can be configured as a light-emitting element that directly emits light of the first and/or second color.

In embodiments, the first color may be different from the second color. The first and/or second colors may be selected from, for example, white, amber, or cyan.

In some embodiments, the first color may be white, such that at least one first light-emitting element is configured to emit white light. In some embodiments, the white light may be light that includes a superposition of at least two, or more than two, light wavelength spectra (e.g., spectral colors). For example, white may be achieved by a light-emitting diode configured to emit blue light with a phosphor coating that converts a portion of the blue light to yellow light, with the mixture of blue and yellow light producing the appearance of white. Different white colors may be characterized by their respective color temperatures. Thereby, in embodiments, the first color may be white with a correlated color temperature (CCT) between 4000K and 6700K.

In an embodiment, the first and/or second color may be cyan (e.g., a color intermediate between blue and green), and thus at least one of the first and/or second light-emitting elements is configured to emit cyan light, respectively. In an embodiment, the cyan light may be characterized by a spectrum of optical wavelengths having a dominant wavelength between 490 nm and 510 nm.

In some embodiments, the second color can be selected from red/magenta, green, blue/cyan, orange, and/or yellow, or any combination thereof. Thus, in some embodiments, at least one second light-emitting element can be configured to emit red/magenta, green, blue/cyan, orange, yellow, and/or amber light.

In some embodiments, the second color may be amber (e.g., between yellow and orange), and thus at least one second light-emitting element is configured to emit amber light. In embodiments, the amber light may be characterized by a spectrum of optical wavelengths having a dominant wavelength between 585 nm and 600 nm.

In some embodiments, the at least one second light-emitting element may be a light-emitting diode (LED) that has been coated with a suitable phosphor coating and is therefore configured to emit amber light, such as light having an optical wavelength spectrum with a dominant wavelength between 585 nm and 600 nm.

Achieving two different color emissions in the same lighting device may provide particular advantages in that several desired functions may be achieved with a single lighting device. In some embodiments, white light produced by the lighting device may be used to enable a lighting function, cyan light to enable an autonomous driving mode, and amber light to enable a signaling function. This may advantageously enable a lighting device architecture that reduces complexity by allowing electrical connections and thermal management to be shared by at least two light-emitting elements. For example, at least one first light-emitting element configured for white or cyan emission may be particularly suitable for use in a daytime running mode or autonomous driving mode, while at least one second light-emitting element configured for amber or cyan emission may be suitable for use in a turn signal mode or autonomous driving mode.

In embodiments, at least one first light-emitting element and at least one second light-emitting element may be disposed on the electrically insulating layer and in direct mechanical contact with the electrically insulating layer. Thus, the at least one first light-emitting element and at least one second light-emitting element may be directly thermally coupled to the electrically insulating layer such that heat generated by the light-emitting elements is efficiently dissipated by the described combined effects of the electrically insulating layer and the interface layer.

In some embodiments, the at least one first light-emitting element and the at least one second light-emitting element can be disposed adjacent to one another such that the light-emitting surfaces of the at least one first light-emitting element and the at least one second light-emitting element are disposed in a common plane. By disposed adjacently, the at least one first light-emitting element and the at least one second light-emitting element can be disposed in close proximity to one another (e.g., in direct contact or with only a thin gap between the at least one first light-emitting element and the at least one second light-emitting element). In some embodiments, the gap between the at least one first light-emitting element and the at least one second light-emitting element can have a width that is 25% or less, less than 10%, and/or less than 5% of the width of the at least one first light-emitting element and/or the at least one second light-emitting element. In embodiments, the gap can be filled with air or another material.

The lighting device 100 may further include a connection portion 120 that also includes portions of the interface layer 101 and the electrical insulation layer 103. The connection portion 120 may further include electrical contact elements 121, 123, and 125, which may electrically connect the lighting device 100 to a power source (not shown). The electrical contact elements 121, 123, and 125 may be in electrical contact with the first and second light-emitting elements 111 and 113, respectively, via lead frames, which may be embedded in the interface layer 101 and the electrical insulation layer 103 and therefore not visible in the figures.

The connection portion may include respective portions of an interface layer and an electrical insulating layer, and at least one electrical contact element. The different thicknesses of the connection portion and the attachment portion allow the at least one electrical contact element to be electrically connected to a power source without electrical contact means such as bond wires and without interfering with the light emission and/or propagation, such as by blocking the optical path of light emitted by the at least one first light-emitting element and the at least one second light-emitting element. In some embodiments, the attachment portion may include respective portions of an interface layer and an electrical insulating layer. In some embodiments, the interface layer and electrical insulating layer portions of the connection portion may be different from the interface layer and electrical insulating layer portions included in the attachment portion.

In some embodiments, the at least one first light-emitting element and the at least one second light-emitting element may be at least partially received within at least one corresponding portion of the mounting portion. The mounting portion may thus support safe mechanical adjustment of the respective positions of the light-emitting elements relative to the lighting device, which may enable precise positioning of the light-emitting elements relative to a corresponding (e.g., external) optical system. Furthermore, by being at least partially received by or embedded within the mounting portion, the corresponding enhanced contact surface may advantageously contribute to beneficial heat transport by the mounting portion away from the light-emitting elements.

For example, as can be seen in FIG. 1A, the thickness of the connecting portion 120 may be less than the thickness of the mounting portion 110, and the connecting portion 120 and the mounting portion 110 may be disposed adjacent to one another to form a step 130 at the transition from the connecting portion 120 to the mounting portion 110. In embodiments, the height of the step may correspond to at least 10% of the maximum thickness of the lighting device, at least 20% of the maximum thickness of the lighting device, and/or at least 40% of the maximum thickness of the lighting device. A lighting device including a step may enable a less complex manufacturing process while protecting the at least one first and/or at least one second light-emitting element from environmental conditions such as dust and humidity.

In embodiments, at least one electrical contact element may be disposed on or in direct mechanical contact with the electrical insulating layer and configured to electrically connect the at least one first light-emitting element and/or the at least one second light-emitting element to a power source. Disposing the at least one electrical contact element on the electrical insulating layer, rather than contacting the lighting device from, for example, the underside, may advantageously allow for the use of a large metallic thermal pad as an interface layer, which may reduce the thermal resistance of the lighting device.

That is, by locating at least one electrical contact element on the upper side of the lighting device, space can be provided for a larger thermal pad provided on the underside of the lighting device that would otherwise be partially covered by the electrical contacts. Thus, in some embodiments, the interface layer can correspond to or include a thermal pad, such as a thermal pad that includes or is metal. In some embodiments, the thermal pad can cover substantially the entire bottom surface of the lighting device. The bottom surface can be opposite the side of the lighting device on which the at least one first light-emitting element and the at least one second light-emitting element are located.

In some embodiments, at least one electrical contact element may include a substantially planar contact portion and may be disposed on an electrically insulating layer within the connection portion. By substantially planar, in some embodiments, the height of the substantially planar contact portion may be understood to be significantly less than the length and/or width of the substantially planar contact portion. In embodiments, the height of the substantially planar contact portion may be 10% or less, or in some embodiments, 5% or less, of the length and/or width of the substantially planar contact portion.

In some embodiments, the substantially planar contacts may be arranged substantially parallel to the bottom surface of the lighting device and/or the respective light-emitting surfaces of the at least one first light-emitting element and/or the at least one second light-emitting element. By arranged substantially parallel, in some embodiments, the angle formed by the substantially planar contacts and the respective light-emitting surfaces may be understood to be less than 10°, less than 5°, and/or less than 3°. Arranging the substantially planar contacts substantially parallel to the bottom surface and/or the respective light-emitting surfaces of the lighting device may advantageously result in a uniform shape of the lighting device, thereby reducing complexity with respect to the overall shape of the lighting device and simplifying the electrical connections of the lighting device.

In embodiments, the at least one substantially planar electrical contact element may correspond to or include at least one contact pad and/or bond pad. The use of a substantially planar electrical contact element is advantageous because it may help enhance the robustness of the lighting device and contribute to achieving a particularly reliable electrical connection. The use of such a contact element may, for example, avoid protruding portions of the contact element, which may help make the lighting device less susceptible to damage (e.g., during manufacturing and/or installation).

In embodiments, at least one electrical contact element may be located on an upper side of the lighting device, the upper side of the lighting device corresponding to the light-emitting side of the lighting device. That is, in embodiments, at least one electrical contact element may be configured to provide electrical contact from the top. Such an architecture may provide a large metallic interface layer on the bottom side of the lighting device, thereby reducing the overall thermal resistance of the lighting device and enabling improved thermal management.

In an embodiment, the lighting device may include at least three electrical contact elements, two of which may be electrically connected to a corresponding one of the at least one first light-emitting element and the at least one second light-emitting element, respectively. One of the at least three electrical contact elements may be electrically connected to both the at least one first light-emitting element and the at least one second light-emitting element.

Three or more electrical contact elements can independently contact at least one first light-emitting element and at least one second light-emitting element. In some embodiments, the electrical contact elements can function as an anode and/or a cathode for at least one first light-emitting element and/or at least one second light-emitting element, respectively. Independently contacting the light-emitting elements advantageously allows the light-emitting elements to be independently turned ON or OFF, thus enabling the light-emitting elements to be used according to one or more predetermined operating modes. The operating modes can correspond, for example, to a daytime running light mode, an autonomous driving mode, and/or a mode in which at least one second light-emitting element is used as a turn signal light, for example.

In some embodiments, the at least one electrical contact element can be electrically connected to the at least one first light-emitting element and/or the at least one second light-emitting element by a lead frame. In embodiments, the lead frame can be or include a metal structure, such as a metal structure embedded in the lighting device, configured to carry power from a power source to the at least one first light-emitting element and/or the at least one second light-emitting element through the at least one electrical contact element. In embodiments, the lead frame can serve to electrically connect the lighting device to a power source. Using a lead frame, such as a metal lead frame embedded in the lighting device, to electrically connect the at least one electrical contact element to the at least one first light-emitting element and/or the at least one second light-emitting element can enable a compact architecture and enhance thermal conductivity.

Figure 1B is a circuit diagram of an example circuit for electrically connecting the lighting device 100 of Figure 1A. 211 and 213 represent the first and second light-emitting elements 111 and 113 of Figure 1A. The light-emitting elements can be electrically connected to a power source (not shown) by electrical contact elements 221, 223, and 225, thereby transferring power from the power source to the first and second light-emitting elements 211 and 213. In the example shown, electrical contact element 223 is electrically connected to both the first and second light-emitting elements 211 and 213. Figure 1C is the circuit diagram of Figure 1B with the direction of current flow reversed, as indicated by the directional arrows through the light-emitting elements 211 and 213.

2A is a perspective view of a lighting device 100'. In the example of FIG. 2A, the lighting device 100' includes an interface layer 101' disposed thereon and an electrical insulating layer 103' disposed thereon. The lighting device 100' may further include a mounting portion 110' including respective portions of the interface layer 101' and the electrical insulating layer 103'. First and second light-emitting elements 111' and 113' may be mounted to the mounting portion 110', and a gap 112' may be formed between the first and second light-emitting elements 111', 113'. The electrical insulating layer 103' may include a supporting portion 103a' and a covering portion 103b', which provide the same advantages as those described above in FIG. 1A.

The lighting device 100' may further include a connection portion 120' that includes respective portions of the interface layer 101' and the electrical insulation layer 103'. The connection portion 120' may include electrical contact elements 121', 123', 124', and 125', which allow the lighting device 100' to be electrically connected to a power source. The thickness of the connection portion 120' may be less than the thickness of the mounting portion 110', and the connection portion 120' and the mounting portion 110' may be disposed adjacent to each other, thereby forming a step 130' at the transition from the connection portion 120' to the mounting portion 110'.

In the example shown in FIG. 2A, the lighting device may include at least first, second, third, and fourth electrical contact elements. Finally, at least one first light-emitting element may be electrically connected to the first and second contact elements, and at least one second light-emitting element may be electrically connected to the third and fourth contact elements.

Figure 2B is a circuit diagram of an exemplary circuit for electrically connecting the lighting device 100' of Figure 2A. The first light-emitting element 211' and the second light-emitting element 213' can be electrically connected to a power source (not shown) by electrical contact elements 221', 223', 224', and 225', thereby enabling power to be conveyed from the power source to the first light-emitting element 211' and the second light-emitting element 213'.

In some embodiments, a lighting device as described above can be included in an automotive lighting system. In some embodiments, the automotive lighting system can correspond to or include an automotive daytime running system, an automotive autonomous driving instruction system, an automotive turn signal lighting system, and/or an automotive headlight lighting system. Accordingly, such an automotive lighting system can include necessary components, including, for example, a controller for controlling the supply of power to at least one first and/or at least one second light-emitting element. The controller can be a separate component and/or can be integrated into the automotive control system to control additional functions.

In some embodiments, the automotive lighting system may further include at least one optical element configured to shape the beam of light emitted from the at least one first light-emitting element and the at least one second light-emitting element. Shaping the beam of light may be understood, for example, as adjusting the direction, intensity, shape, or pattern of the beam of light emitted from the at least one first and/or at least one second light-emitting element. Shaping the beam of light emitted from each of the at least one first light-emitting element and the at least one second light-emitting element using at least one common optical element may advantageously support the use of the at least one first light-emitting element and the at least one second light-emitting element in the automotive lighting system in at least two predetermined operating modes. In some embodiments, the at least one optical element may include one or more reflectors and/or lens elements. For example, one or more lens elements may be incorporated into an exterior glass portion through which the beam of light passes toward the outside.

In some embodiments, the automotive lighting system may further include a controller configured to control at least one first and/or at least one second light-emitting element, respectively, to be turned ON and/or OFF according to at least one predetermined operating mode. As previously mentioned, the controller may be a separate controller or a subcomponent of a control system. The controller may correspond to a suitable dedicated controller or may correspond to or include a microprocessor.

In some embodiments, the predetermined operating mode is one of: a daytime driving mode in which the first color is white, at least one first light-emitting element is ON, and at least one second light-emitting element is OFF; a turn signal mode in which the second color is amber, at least one second light-emitting element is turned ON and OFF, particularly periodically, and at least one first light-emitting element is OFF; a first autonomous driving mode in which the first color is cyan, at least one first light-emitting element is ON, and at least one second light-emitting element is OFF; and a second autonomous driving mode in which the second color is cyan, at least one first light-emitting element is OFF, and at least one second light-emitting element is ON.

Thus, in some embodiments, the lighting device may include at least one first light-emitting element configured to emit either white light (e.g., for use in a daytime driving mode) and/or cyan light (e.g., for use in a first autonomous driving mode), and at least one second light-emitting element configured to emit either amber light (e.g., for use in a turn signal mode) or cyan light (e.g., for use in a second autonomous driving mode).

For example, when used as a daytime running light or in a first autonomous driving mode, at least one first light-emitting element may be ON, thereby turning at least one second light-emitting element OFF. As a further example, in a turn signal mode, at least one first light-emitting element may be OFF and at least one second light-emitting element may be turned ON and OFF (e.g., periodically) to indicate a turn of the vehicle. As a further example, in a second autonomous driving mode, at least one first light-emitting element may be OFF and at least one second light-emitting element may be ON to indicate that the vehicle is driving autonomously.

In some embodiments, the automotive lighting system further includes a heat sink, whereby the interface layer can be positioned in direct mechanical contact with the heat sink to conduct heat generated by the at least one first light-emitting element and/or the at least one second light-emitting element to the heat sink. This can advantageously enable enhanced thermal management of the automotive lighting system, and in particular the lighting devices included therein.

Figure 5 is a flow diagram of a method for manufacturing a lighting device, such as lighting device 100 or 100' of Figures 1A and 2A. In the example shown in Figure 5, the method includes providing an electrical insulation layer (502). A first light-emitting element and a second light-emitting element may be provided (504) and disposed on the electrical insulation layer (506). An electrical contact element may be provided (508) and disposed on the electrical insulation layer (510). The electrical contact element may be electrically coupled to at least one of the first light-emitting element and the second light-emitting element (512).

FIG. 3 is a diagram of an exemplary vehicle headlamp system 300 that may incorporate the lighting device 100 or 100' of FIG. 1A or 2A. The exemplary vehicle headlamp system 300 shown in FIG. 3 includes a power line 302, a data bus 304, an input filter and protection module 306, a bus transceiver 308, a sensor module 310, an LED-to-DC (DC-to-DC) module 312, a logic low dropout (LDO) module 314, a microcontroller 316, and an active headlamp 318. In an embodiment, the active headlamp 318 may include all or a portion of a lighting device, such as the lighting device 100 of FIG. 1A or the lighting device 100' of FIG. 2A.

The power line 302 can have an input for receiving power from the vehicle, and the data bus 304 can have inputs and outputs for exchanging data between the vehicle and the vehicle headlamp system 300. For example, the vehicle headlamp system 300 can be instructed from elsewhere in the vehicle to turn on turn signaling or turn on the headlamps, and can send feedback to other locations in the vehicle as needed. The sensor module 310 can be communicatively coupled to the data bus 304 and can provide additional data to the vehicle headlamp system 300 or elsewhere in the vehicle related to, for example, environmental conditions (e.g., time of day, rain, fog, or ambient light levels), vehicle status (e.g., parked, moving, speed, or direction of travel), and the presence/location of other objects (e.g., vehicles or pedestrians). The vehicle headlamp system 300 can also include a headlamp controller separate from the vehicle controller communicatively coupled to the vehicle data bus. In FIG. 3, the headlamp controller can be a microcontroller, such as microcontroller (μc) 316. The microcontroller 316 may be communicatively coupled to the data bus 304.

The input filter and protection module 306 may be electrically coupled to the power line 302 and may support various filters to, for example, reduce conducted emissions and provide power immunity. Additionally, the input filter and protection module 306 may provide electrostatic discharge (ESD) protection, load dump protection, alternator field decay protection, and/or reverse polarity protection.

The LED DC/DC module 312 may be coupled between the filter and protection module 306 and the active headlamp 318 to receive the filtered power and provide a drive current to power the LEDs in the LED array of the active headlamp 318. The LED DC/DC module 312 may have an input voltage between 7 and 18 volts, with a nominal voltage of approximately 13.2 volts, and an output voltage slightly (e.g., 0.3 volts) higher than the maximum voltage of the LED array (e.g., as determined by coefficients or local calibration, operating condition adjustments due to load, temperature, or other factors).

The logic LDO module 314 may be coupled to the input filter and protection module 306 to receive filtered power. The logic LDO module 314 may also be coupled to the microcontroller 316 and the active headlamp 318 to provide power to the microcontroller 316 and/or a silicon backplane (e.g., CMOS logic) within the active headlamp 318.

The bus transceiver 308 may include, for example, a universal asynchronous receiver/transmitter (UART) or a serial peripheral interface (SPI) and may be coupled to the microcontroller 316. The microcontroller 316 may convert vehicle input based on or including data from the sensor module 310. The converted vehicle input may include a video signal that can be transferred to an image buffer within the active headlamp module 318. Additionally, the microcontroller 316 may load a default image frame and test for open/short pixels during startup. In an embodiment, the SPI interface may load a CMOS image buffer. The image frame may be a full frame, a differential frame, or a partial frame. Other functions of the microcontroller 316 include a control interface monitoring CMOS status, including die temperature, as well as a logic LDO output. In an embodiment, the LED DC/DC output may be dynamically controlled to minimize headroom. In addition to providing image frame data, the microcontroller 316 may also control other headlamp functions, such as complementary use in combination with side marker or turn signal lights and/or daytime running light activation.

FIG. 4 is a diagram of another exemplary vehicle headlamp system 400. The exemplary vehicle headlamp system 400 shown in FIG. 4 includes an application platform 402, two lighting devices 406 and 408, and optical systems 410 and 412. The lighting devices 406 and 408 may be LED lighting systems such as the lighting devices 100 or 100' of FIG. 1A or 2A, or may include lighting devices 100 or 100' as well as some of the other modules in the vehicle headlamp system 300 of FIG. 3. In the latter embodiment, the lighting devices 406 and 408 may be vehicle headlamp subsystems.

The lighting device 406 may emit a beam of light 416 (shown between arrows 416a and 416b in FIG. 4). In the embodiment shown in FIG. 4, a secondary optic 410 is adjacent to the lighting device 408, and light emitted from the lighting device 408 passes through the secondary optic 410. Similarly, a secondary optic 412 is adjacent to the lighting device 406, and light emitted from the lighting device 406 passes through the secondary optic 412. In an alternative embodiment, the vehicle headlamp system does not include secondary optics 410/412.

If included, secondary optics 410/412 may be or include one or more light guides. One or more light guides may be edge-lit or have an internal opening that defines the interior edge of the light guide. Illumination devices 408 and 406 (or active headlamps in a vehicle headlamp subsystem) may be inserted into the internal opening of one or more light guides to inject light into the interior edge (internal aperture light guides) or exterior edge (edge-lit light guides) of the one or more light guides. In embodiments, one or more light guides may shape the light emitted by illumination devices 408 and 406 in a desired manner, such as, for example, a gradient, a chamfered distribution, a narrow distribution, a wide distribution, or an angular distribution.

The application platform 402 can provide power and/or data to the lighting devices 406 and/or 408 via lines 404, which can include one or more or portions of the power lines 302 and data bus 304 of FIG. 3. One or more sensors (which may be sensors within the exemplary vehicle headlamp system 300 or other additional sensors) can be internal or external to the housing of the application platform 402. Alternatively, or in addition, as shown in the exemplary vehicle headlamp system 300 of FIG. 3, each lighting device 408 and 406 can include its own sensor module, connection and control module, power module, and/or LED array.

In an embodiment, vehicle headlamp system 400 may represent an automobile with a steerable light beam, where LEDs can be selectively activated to provide steerable light. For example, an array of LEDs may be used to define or project a shape or pattern, or to illuminate only selected sections of a road. In an exemplary embodiment, the infrared camera or detector pixels in lighting devices 406 and 408 may be sensors (e.g., similar to the sensors in sensor module 310 of FIG. 3) that identify portions of a scene (e.g., a road or crosswalk) that require illumination.

Although embodiments have been described in detail, those skilled in the art will appreciate, in light of the present description, that modifications can be made to the embodiments described herein without departing from the spirit of the inventive concept. Accordingly, it is not intended that the scope of the invention be limited to the specific embodiments illustrated and described.

Claims (18)

an electrically insulating layer having a top surface and a metallized bottom surface, the electrically insulating layer having a thermal conductivity greater than 10 W/(m*K);
at least one first light emitting element on the top surface of the electrically insulating layer, the first light emitting element configured to emit light of a first color;
at least one second light-emitting element on the top surface of the electrically insulating layer, the second light-emitting element configured to emit light of a second color;
at least three electrical contact elements at least partially on the top surface of the electrically insulating layer,
two of the at least three electrical contact elements are each electrically coupled to a corresponding one of the at least one first light-emitting element and the at least one second light-emitting element, and one of the at least three electrical contact elements is electrically coupled to both the at least one first light-emitting element and the at least one second light-emitting element;
A lighting device, wherein the electrical insulation layer includes a connection portion in which the at least three electrical contact elements are arranged, and an attachment portion in which the at least one first light-emitting element and the at least one second light-emitting element are arranged, and the thickness of the connection portion is smaller than the thickness of the attachment portion . The lighting device of claim 1, wherein the thermal conductivity of the electrical insulation layer is greater than 100 W/(m*K). The lighting device of claim 1, wherein the electrically insulating layer comprises a ceramic material. The lighting device of claim 1, wherein the first color is different from the second color. The lighting device of claim 1, wherein at least one of the first color or the second color is selected from the group consisting of white, amber, and cyan. The lighting device according to claim 1 , wherein the mounting portion and the connecting portion are adjacent to each other and form a step at the transition from the connecting portion to the mounting portion. The lighting device of claim 1 , wherein the at least one first light emitting element and the at least one second light emitting element are at least partially disposed within the mounting portion. The lighting device of claim 1 , wherein the at least three electrical contact elements include substantially planar contact portions and are disposed on the electrically insulating layer and within the connecting portions. The lighting device of claim 1, wherein the at least one first light-emitting element and the at least one second light-emitting element are adjacent to each other, and the light-emitting surfaces of the at least one first light-emitting element and the at least one second light-emitting element are arranged in a common plane. The lighting device of claim 1, wherein the at least three electrical contact elements include at least first, second, third, and fourth electrical contact elements, the at least one first light-emitting element being electrically coupled to the first and second electrical contact elements, and the at least one second light-emitting element being electrically coupled to the third and fourth electrical contact elements. 1. A lighting system for an automobile, comprising:
an electrically insulating layer having a top surface and a metallized bottom surface, the electrically insulating layer having a thermal conductivity greater than 10 W/(m*K);
at least one first light emitting element on the top surface of the electrically insulating layer, the first light emitting element configured to emit light of a first color;
at least one second light-emitting element on the top surface of the electrically insulating layer, the second light-emitting element configured to emit light of a second color;
at least three electrical contact elements at least partially on the top surface of the electrically insulating layer,
two of the at least three electrical contact elements are each electrically coupled to a corresponding one of the at least one first light-emitting element and the at least one second light-emitting element, and one of the three electrical contact elements is electrically coupled to both the at least one first light-emitting element and the at least one second light-emitting element;
An automotive lighting system comprising a lighting device, wherein the electrical insulation layer includes a connection portion in which the at least three electrical contact elements are arranged, and an attachment portion in which the at least one first light-emitting element and the at least one second light-emitting element are arranged, and the thickness of the connection portion is smaller than the thickness of the attachment portion . 12. The automotive lighting system of claim 11 , further comprising at least one optical element configured to shape beams of light emitted from the at least one first light-emitting element and the at least one second light-emitting element. 12. The automotive lighting system of claim 11, further comprising a controller configured to control at least one of the at least one first light-emitting element or the at least one second light-emitting element, respectively, to switch at least one of ON or OFF according to at least one predetermined operating mode. 14. The automotive lighting system of claim 13, wherein the first color is white and the predetermined operating mode includes a daytime running mode in which the controller is configured to turn the at least one first light-emitting element ON and turn the at least one second light-emitting element OFF. 14. The automotive lighting system of claim 13, wherein the second color is amber and the predetermined operating modes include a turn signal mode in which the controller is configured to cycle the at least one second light-emitting element ON and OFF and to turn the at least one first light-emitting element OFF. 14. The automotive lighting system of claim 13, wherein the first color is cyan and the predetermined operating mode includes a first autonomous driving mode in which the controller is configured to turn on the at least one first light-emitting element and turn off the at least one second light-emitting element. 14. The automotive lighting system of claim 13, wherein the second color is cyan, and the predetermined operating mode includes a second autonomous driving mode in which the controller is configured to turn off the at least one first light-emitting element and turn on the at least one second light-emitting element. 1. A method of manufacturing a lighting device, comprising:
providing an electrically insulating layer, the electrically insulating layer having a top surface and a bottom surface and a thermal conductivity greater than 10 W/(m*K);
providing at least one first light emitting element configured to emit light of a first color and at least one second light emitting element configured to emit light of a second color;
disposing the at least one first light emitting element and the at least one second light emitting element on the top surface of the electrical insulating layer;
providing at least three electrical contact elements;
disposing the at least three electrical contact elements on the top surface of the at least partially metallized electrically insulating layer;
electrically coupling two of the at least three electrical contact elements to corresponding ones of the at least one first light emitting element and the at least one second light emitting element, respectively;
electrically coupling one of the at least three electrical contact elements to both the at least one first light-emitting element and the at least one second light-emitting element;
The method, wherein the electrical insulation layer includes a connection portion in which the at least three electrical contact elements are arranged, and an attachment portion in which the at least one first light-emitting element and the at least one second light-emitting element are arranged, and the thickness of the connection portion is smaller than the thickness of the attachment portion .