LED headlights use free-form optics and ceramic frame

CeramTec produced the ceramic frame, and Docter Optics developed the free-form lenses, for Hella LED headlights used on the Cadillac Escalade SUV as standard equipment.

Content Dam Leds En Articles 2008 05 Led Headlights Use Free Form Optics And Ceramic Frame Leftcolumn Article Thumbnailimage File
Two suppliers recently described their involvement in the LED headlights that Hella KGaA Hueck & Co. is supplying for the Cadillac Escalade Platinum Sports Utility Vehicle that enters serial production this summer - see Related Stories.

The distinctive design of the LED headlamp is based around seven free-form glass projection lenses that are being used for the first time anywhere in the world, according to Hella.

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All-LED SUV headlight
The projection lenses were supplied by Docter Optics, while the multi-chip LEDs are mounted on a specially developed CeramCool ceramic frame produced by CeramTec AG’s Electronics Division.

Docter Optics’ projection lenses

Docter Optics produced the sophisticated “free-form” lenses for the Escalade’s full-LED headlights. Free-form lenses make it possible, for example, to “shape” light to meet the needs of a specific application with exceptional precision, the company says.

The assemblies in the Escalade integrate not only high- and low-beam functionality, but also daytime running lights and position lights as well as the side markers that are obligatory in the US.

Docter Optics' proprietary DOC3D process permits large-scale production of aspheres and free-form lenses for sophisticated illumination applications, including economical production of special lenses for these LED headlights.

CeramTec’s ceramic frame

The partially transparent frame is produced using a dry pressing process and is then metallized. To meet strict customer requirements, a special process had to be developed that observed the lowest tolerances and used an absolutely faultless metallization, CeramTec said.

Each headlight is equipped with 7 LEDs and subsequently fitted with the ceramic CeramCool. The LED solution is particularly robust and works reliably in temperatures ranging from -40°C to +125°C.

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