DESC:FIELD OF INVENTION
[0001] The present disclosure relates to lighting systems for military vehicles, and more particularly to a modular LED-based headlight system with selectable high beam, low beam, and combat modes for armored vehicles.
BACKGROUND OF THE INVENTION
[0002] Lighting systems for military vehicles play a crucial role in ensuring operational effectiveness and safety across various combat and non-combat scenarios. These systems must provide adequate illumination for navigation and situational awareness while also offering flexibility to adapt to different tactical requirements.
[0003] Armored vehicles, such as infantry fighting vehicles and armored personnel carriers, operate in diverse environments and conditions, ranging from urban areas to rugged terrains and from daylight to complete darkness. This variability necessitates lighting solutions that can accommodate different visibility needs without compromising the vehicle's tactical advantages or crew safety.
[0004] Conventional lighting systems for armored vehicles typically consist of separate units for different functions, such as standard headlights for regular driving and additional tactical lights for combat situations. This approach often results in increased complexity, higher maintenance requirements, and potential vulnerabilities due to multiple external components.
[0005] Some existing solutions attempt to address the challenges. In one patent application US 8777459 describes an LED-based lighting system for military vehicles that incorporates both visible and infrared light sources. However, the system does not integrate all required lighting modes into a single, compact unit, potentially limiting its retrofitting capabilities and overall versatility.
[0006] . In another patent application US 9840186, the invention discloses a vehicle lamp with selectable modes. While the system offers some flexibility in lighting output, it is not specifically designed for the rigorous demands of armored military vehicles and lack the necessary ruggedization and electromagnetic interference protection required for combat environments.
[0007] Keeping in view the challenges associated with the state of the art, there is a need for an integrated, multi-mode LED headlight system for armored vehicles that combines high beam, low beam, and combat lighting capabilities in a single, robust unit. Such a system would enhance operational flexibility, simplify installation and maintenance, and improve overall vehicle effectiveness in various tactical scenarios.
OBJECTIVES OF THE INVENTION
[0008] The primary objective of the present invention is to provide an integrated, multi-mode LED headlight system for armored vehicles that combines high beam, low beam, and combat lighting capabilities in a single, robust unit.
[0009] Another objective of the present invention is to enhance operational flexibility for armored vehicles by offering selectable lighting modes suitable for various tactical scenarios.
[0010] Another objective of the present invention is to simplify installation and maintenance of lighting systems on armored vehicles by consolidating multiple lighting functions into a single unit.
[0011] Another objective of the present invention is to improve the overall effectiveness and safety of armored vehicles in diverse operating environments and conditions.
[0012] Another objective of the present invention is to offer a lighting solution that can be easily retrofitted to existing armored vehicles without requiring extensive modifications.
[0013] Yet another objective of the present invention is to provide a ruggedized lighting system capable of withstanding the harsh conditions and potential impacts encountered in combat situations.
[0014] Yet another objective of the present invention is to incorporate electromagnetic interference protection to ensure reliable operation in combat environments.
[0015] Yet another objective of the present invention is to reduce the number of external components on armored vehicles, thereby minimizing potential vulnerabilities and improving overall vehicle survivability.
[0016] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.
SUMMARY OF THE INVENTION
[0017] The present invention discloses a LED-based headlight system for armored vehicles is provided. The system includes a single, modular LED-based headlight unit with selectable high beam, low beam, and combat mode. The combat mode utilizes low-intensity, directional lighting or IR-compatible output for stealth operations. The system is integrated into a rugged housing, programmable through vehicle systems or manual toggle, and is retrofittable to existing armored vehicles.
[0018] According to other aspects of the present invention, the LED-based headlight system include advanced thermal management features and comply with military EMI/EMC standards. The system may be designed to switch modes based on user input or external triggers, eliminating the need for multiple lighting devices. The combat mode may support IR-capable stealth operations, enhancing operational flexibility for armored vehicles operating in varying conditions.
BRIEF DESCRIPTION OF FIGURES
[0019] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0020] Figure 1 illustrates a front view of a circular headlight assembly for an armored vehicle, according to aspects of the present disclosure.
[0021] Figure 2 depicts a side sectional view of the headlight assembly of FIG. 1, according to an embodiment.
[0022] Common reference numerals are used throughout the figures to indicate similar features.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The following detailed description and embodiments set forth herein below are merely exemplary out of the wide variety and arrangement of instructions which can be employed with the present invention. The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. All the features disclosed in this specification may be replaced by similar other or alternative features performing similar or same or equivalent purposes. Thus, unless expressly stated otherwise, they all are within the scope of the present invention.
[0024] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0025] The terms and words used in the following description and claims are not limited to the bibliographical meanings but are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.
[0026] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
[0027] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof.
[0028] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
[0029] Accordingly, the present disclosure relates to LED headlight systems (100) for armored vehicles. More specifically, the disclosure pertains to a modular LED-based headlight system (100) that incorporates multiple operational modes within a single unit. The system may provide high beam, low beam, and combat mode functionalities, addressing the diverse lighting requirements of armored vehicles in various operational scenarios.
[0030] In some cases, the LED headlight system (100) may be designed for integration into existing armored vehicle platforms, such as the BMP-2 or similar vehicles. The system may offer enhanced operational flexibility by allowing users to switch between different lighting modes based on mission requirements or environmental conditions.
[0031] The disclosed headlight system (100) may incorporate advanced features such as programmable control logic, thermal management systems (110), and compliance with military standards for electromagnetic interference (EMI) and electromagnetic compatibility (EMC). These features may contribute to the system's reliability and suitability for use in demanding military environments.
[0032] In some implementations, the combat mode of the headlight system (100) may utilize low-intensity directional lighting or infrared (IR) compatible output. This feature may enable stealth operations by reducing visible light emissions while maintaining compatibility with night vision equipment.
[0033] The modular nature of the headlight system (100) may allow for retrofitting onto existing vehicles, potentially reducing the need for extensive modifications to vehicle structures or electrical systems. This approach may offer a cost-effective solution for upgrading the lighting capabilities of armored vehicle fleets.
[0034] In some cases, the LED headlight system (100) may include the following components:
[0035] a) A sealed circular housing (102) as shown in Figure 1, which may incorporate IP67 sealing to protect internal components from environmental factors and define an internal cavity providing structural support for all internal components.
[0036] b) A central mounting hub (104) visible in figure 2, which may be mechanically secured within the housing (102) and serve as a primary attachment point for the LED array. The hub may be configured with mounting surfaces and electrical connection pathways, serving as a mechanical and thermal interface between components.
[0037] c) An LED array (106) mounted directly to the central mounting hub (104) within the housing (102), which may comprise multiple LEDs arranged for different lighting modes and electrically connected to provide selectable illumination outputs. In some implementations, the LED array (106) may incorporate 850nm IR LEDs for night vision goggle (NVG) compatibility and be connected to the control interface through internal wiring for power distribution and mode control signals.
[0038] d) A reflector (108) positioned around the LED array (106) and mechanically coupled to the central mounting hub (104), which may be configured with shaped surfaces to optimize light distribution and direct illumination for various beam patterns. The reflector may be positioned in close proximity to the LED array to effectively direct light output and optimize beam patterns.
[0039] e) A thermal management system (110) integrated into the housing (102) design and thermally coupled to the LED array (106) through the central mounting hub (104), as indicated by the structural features in Figure 2. This system may include a MIL-STD thermal coating to enhance heat dissipation and be configured to regulate operating temperatures and prevent overheating through direct thermal contact with the LED array.
[0040] f) A control interface (112) mounted on the housing (102) and electrically connected to the LED array (106), represented by the side-mounted connector in Figure 1, which may be configured to receive power and control signals for mode selection and system operation. The control interface may be linked to the vehicle's electrical system to receive power and control commands.
[0041] g) Internal support structures (114) mechanically connected between the housing (102) walls and the central mounting hub (104), visible in Figure 1, including horizontal bars that are configured to divide the internal space into distinct zones and provide structural rigidity. These structures may provide mechanical stability and component isolation.
[0042] h) EMI shielding (116) incorporated into the housing (102) design and configured with conductive materials to mitigate electromagnetic interference. The EMI shielding may encompass internal components to provide electromagnetic interference protection for reliable operation in combat environments.
[0043] The LED headlight system may be powered by a 24V DC supply connected through the control interface (112). The housing (102) may feature mounting points (118) distributed around its perimeter, as shown in Figure 1, which are integrated with the housing structure and configured as attachment interfaces for secure mounting to the vehicle.
[0044] In some implementations, the LED array (106) may be connected to the control interface (112) through internal wiring for power distribution and mode control signals, which may in turn be linked to the vehicle's electrical system. The reflector (108) may be positioned in proximity to the LED array (106) and mechanically coupled to the central mounting hub (104) to direct light output effectively. The thermal management system (110) may be in direct thermal contact with heat-generating components such as the LED array (106) through the central mounting hub (104) to regulate operating temperatures.
[0045] The EMI shielding (116) may encompass the internal components to mitigate electromagnetic interference, while the IP67 sealing of the housing (102) may work in conjunction with the mounting points (118) to ensure environmental protection. The internal support structures (114) may provide mechanical stability and component isolation, while the central mounting hub (104) serves as a mechanical and thermal interface between components.
[0046] In some cases, the LED headlight system (100) may incorporate three distinct operational states to accommodate various mission requirements. These operational states may include a high-beam mode, a low-beam mode, and a combat mode.
[0047] The high-beam mode may utilize high-lumen LED arrays to provide maximum illumination for enhanced visibility during normal driving conditions. In some implementations, the low-beam mode may employ pulse-width modulation (PWM) dimming techniques to reduce light output while maintaining a suitable beam pattern for convoy travel or urban environments.
[0048] Alternatively, the low-beam mode may utilize separate optical components to shape the light output for reduced glare and appropriate road illumination. These separate optics may be integrated into the headlight assembly to maintain a compact form factor.
[0049] The combat mode of the LED headlight system (100) may offer specialized lighting capabilities for tactical operations. In some cases, the combat mode may completely disable visible light output to minimize detection during stealth missions. Alternatively, the combat mode may activate infrared (IR) spectrum emitters, allowing for compatibility with night vision equipment while reducing visible signatures.
[0050] The LED headlight system (100) may incorporate thermal management features to ensure reliable operation in demanding environments. In some implementations, a thermal sensor may be integrated into the headlight assembly to monitor internal temperatures and implement overheat protection measures. This thermal sensor may work in conjunction with control logic to implement overheat protection measures, such as reducing LED output or activating cooling systems when temperature thresholds are exceeded, with the thermal management system (110) maintaining direct thermal contact with the LED array (106) through the central mounting hub (104).
[0051] In some cases, the LED headlight system (100) may be designed for integration with the vehicle's existing control systems. The headlight assembly may interface with the vehicle's control bus, allowing for seamless operation and mode switching through existing vehicle controls or dedicated switches. This integration may enable automatic mode selection based on vehicle status or mission parameters, enhancing operational efficiency and reducing driver workload.
[0052] The control interface (112) of the LED headlight system (100) may support both manual and automated operation through its connection to the vehicle's electrical system. In some implementations, a three-position switch may be provided for direct user control of the lighting modes. Alternatively, the system may respond to digital commands from the vehicle's network through the control interface (112), allowing for centralized control and coordination with other vehicle systems.
[0053] In some cases, the method of operation for the LED headlight system (100) may include the following steps:
[0054] Powering on the LED headlight system (100) by connecting the system to a 24V DC power supply from the vehicle's electrical system.
[0055] Initializing the control logic within the LED headlight system (100), which may include setting default parameters and performing system checks.
[0056] Receiving a mode selection input, which may be transmitted through the vehicle's control bus or via a manual switch connected to the LED headlight system (100).
[0057] Processing the mode selection input using software logic implemented within the LED headlight system's (100) microcontroller.
[0058] Activating the appropriate LED arrays and optical components based on the selected mode:
[0059] For high beam mode:
• Energizing the high-lumen LED arrays (106) to provide maximum illumination.
• Configuring the reflector (108) or light-directing elements to achieve a wide, long-range beam pattern.
[0060] For low beam mode:
• Activating a subset of LEDs or reducing power to the LED arrays (106) through pulse-width modulation (PWM) dimming.
• Adjusting the optical components including the reflector (108) to shape the light output for reduced glare and appropriate road illumination.
[0061] For combat mode:
• Disabling visible light output or activating infrared (IR) spectrum emitters within the LED array (106).
• Configuring the reflector (108) and other optical elements to optimize the IR light distribution for night vision compatibility.
[0062] Monitoring thermal conditions within the LED headlight system (100) using integrated temperature sensors.
[0063] Implementing thermal management protocols as needed, which may include adjusting LED output or activating cooling systems to maintain optimal operating temperatures.
[0064] Continuously monitoring for new mode selection inputs or changes in vehicle status that may trigger automatic mode switching.
[0065] In some implementations, the method of operation may utilize relay control for switching between modes. This approach may involve:
• Receiving a mode selection signal through the control interface.
• Activating or deactivating specific relays associated with each lighting mode.
• Routing power to the appropriate LED arrays and optical components based on the relay configurations.
• Verifying the successful activation of the selected mode through feedback mechanisms or sensor readings.
[0066] The method of operation may also incorporate adaptive features, such as:
• Adjusting light output based on ambient light conditions detected by integrated sensors.
• Coordinating mode changes with other vehicle systems, such as activating combat mode inconjunction with other stealth-related vehicle functions.
• Logging operational data, including mode usage and thermal management events, for maintenance and performance analysis purposes.
[0067] In some cases, the LED headlight system (100) for armored vehicles may offer several advantages over conventional lighting systems. The integration of multiple lighting modes into a single unit may enhance operational flexibility, allowing vehicle operators to adapt quickly to changing mission requirements or environmental conditions.
[0068] The modular design of the LED headlight system (100) may simplify installation and maintenance procedures. In some implementations, the system may be retrofitted into existing armored vehicle platforms without requiring extensive modifications to the vehicle structure or electrical systems. This approach may reduce installation time and costs associated with upgrading vehicle lighting capabilities.
[0069] The incorporation of advanced thermal management features and military-grade construction may contribute to improved reliability in demanding operational environments. In some cases, the system's compliance with military standards for electromagnetic interference (EMI) and electromagnetic compatibility (EMC) may enhance overall vehicle effectiveness by reducing potential conflicts with other onboard electronic systems.
[0070] The combat mode functionality may provide tactical advantages during stealth operations. By offering low-intensity directional lighting compatible output, the system may enable vehicle operators to maintain situational awareness while minimizing visible light emissions. This capability may enhance vehicle survivability in high-threat environments.
[0071] In some implementations, the integration of the LED headlight system (100) with the vehicle's control bus may streamline operational procedures. The ability to switch between lighting modes through existing vehicle controls or automated systems may reduce driver workload and improve overall mission effectiveness.
[0072] The use of LED technology may offer potential benefits in terms of energy efficiency and longevity compared to traditional halogen lighting systems. In some cases, this may contribute to reduced maintenance requirements and improved operational readiness for armored vehicle fleets.
[0073] The multi-mode functionality of the LED headlight system may enhance vehicle versatility across a range of operational scenarios, from standard road travel to tactical maneuvers. This flexibility may improve the overall utility of armored vehicles in diverse mission profiles.
[0074] Features of any of the examples or embodiments outlined above may be combined to create additional examples or embodiments without losing the intended effect. It should be understood that the description of an embodiment or example provided above is by way of example only, and various modifications could be made by one skilled in the art. Furthermore, one skilled in the art will recognise that numerous further modifications and combinations of various aspects are possible. Accordingly, the described aspects are intended to encompass all such alterations, modifications, and variations that fall within the scope of the appended claims.
,CLAIMS:WE CLAIM:

1. A LED-based headlight system (100) with selectable modes for armored vehicles, comprising:
• a sealed circular housing (102) incorporating a sealing to protect internal components from environmental factors;
• a central mounting hub (104) secured within the housing (102) and serving as an primary attachment point for the LED array (106);
• the LED array (106) mounted directly to the central mounting hub (104) within the housing (102), and comprising multiple LEDs arranged for different lighting modes and electrically connected to provide selectable illumination outputs;
• a reflector (108) positioned around the LED array (106) and mechanically coupled to the central mounting hub (104) and configured with shaped surfaces to optimize light distribution and direct illumination for various beam patterns;
• a thermal management system (110) integrated into the housing (102) design and coupled to the LED array (106) through the central mounting hub (104) and configured to dissipate heat generated during LED operation;
• a control interface (112) mounted on the housing (102) and connected to the LED array (106) and configured to receive power and control signals for mode selection and system operation;
• a plurality of internal support structures (114) mechanically connected between the housing (102) walls and the central mounting hub (104), the structures including horizontal bars and configured to divide internal space into distinct zones and provide structural rigidity;
• an EMI shielding (116) incorporated into the housing (102) design and configured with conductive materials to mitigate electromagnetic interference;
• a plurality of mounting points (118) distributed around a perimeter of the housing (102) and integrated with the housing structure, the points configured as attachment interfaces for secure mounting to a vehicle;
wherein,
• the LED array (106) is connected to the control interface (112) through internal wiring for power distribution and mode control signals;
• the control interface (112) is linked to a vehicle's electrical system to receive power and control commands;
• the reflector (108) is positioned in proximity to the LED array (106) to direct light output and optimize beam patterns;
• the thermal management system (110) is in thermal contact with the LED array (106) to regulate operating temperatures and prevent overheating;
• the EMI shielding (116) encompasses internal components to mitigate electromagnetic interference;
• the internal support structures (114) provide mechanical stability and component isolation;
• the mounting points (118) enable secure attachment to vehicle structures;
• the central mounting hub (104) serves as a mechanical and thermal interface between components; and
• the system provides selectable high beam, low beam, and combat modes within a single modular unit.
2. The LED-based headlight system as claimed in claim 1, wherein the LED array (106) incorporates 850nm IR LEDs for night vision goggle compatibility.
3. The LED-based headlight system as claimed in claim 1, wherein the thermal management system (110) includes a MIL-STD thermal coating to enhance heat dissipation.
4. The LED-based headlight system as claimed in claim 1, wherein the system is powered by a 24V DC supply connected through the control interface (112).
5. The LED-based headlight system as claimed in claim 1, wherein the high-beam mode utilizes high-lumen LED arrays (106) to provide maximum illumination for enhanced visibility during normal driving conditions.
6. The LED-based headlight system as claimed in claim 1, wherein the low-beam mode employs pulse-width modulation dimming techniques to reduce light output while maintaining a suitable beam pattern.
7. The LED-based headlight system as claimed in claim 1, wherein the combat mode completely disables visible light output to minimize detection during stealth missions or activates infrared spectrum emitters for compatibility with night vision equipment.
8. The LED-based headlight system as claimed in claim 1, further comprising a thermal sensor integrated into the headlight assembly to monitor internal temperatures and implement overheat protection measures.
9. The LED-based headlight system as claimed in claim 1, wherein the control interface (112) supports both manual operation via a three-position switch and automated operation through digital commands from a vehicle's network.
10. A method of operating a LED headlight system (100) for armored vehicles, comprising:
• powering on the LED headlight system (100) by connecting the system to a 24V DC power supply from a vehicle's electrical system;
• initializing control logic within the LED headlight system (100) including setting default parameters and performing system checks;
• receiving a mode selection input transmitted through a vehicle's control bus or via a manual switch;
• processing the mode selection input using software logic implemented within a microcontroller;
• activating appropriate LED arrays (106) and optical components based on a selected mode by energizing high-lumen LED arrays (106) and configuring a reflector (108) for high beam mode, activating a subset of LEDs or reducing power through pulse-width modulation dimming and adjusting optical components for low beam mode, or disabling visible light output or activating infrared spectrum emitters for combat mode;
• monitoring thermal conditions within the LED headlight system (100) using integrated temperature sensors;
• implementing thermal management protocols including adjusting LED output or activating cooling systems to maintain optimal operating temperatures; and
• continuously monitoring for new mode selection inputs or changes in vehicle status that trigger automatic mode switching.