LED planar light source and low-profile headlight constructed therewith

A light source comprising:

• a light emitting semiconductor device;
• a support substrate having a generally planar reflective surface that supports the semiconductor device, the light emitting semiconductor device heat sinking via the support substrate;
• and
• a curved reflector having a concave reflective surface, the light emitting semiconductor device arranged between the generally planar reflective surface and the concave reflective surface, the support substrate and the curved reflector together defining a light aperture through which light produced by the light emitting semiconductor device passes, the curved reflector including:
• a light transmissive encapsulant that encapsulates the light emitting semiconductor device and at least a portion of the generally planar reflective surface, the encapsulant including a convex generally parabolic encapsulant surface;
• and
• a reflective layer disposed on the convex generally parabolic encapsulant surface, an interface between the reflective layer and the encapsulant corresponding to the concave generally parabolic surface of the curved reflector.

A light source comprising:

• a light emitting semiconductor device;
• a support substrate having a generally planar reflective surface that supports the semiconductor device;
• and
• a curved reflector having a concave reflective surface, the light emitting semiconductor device arranged between the generally planar reflective surface and the concave reflective surface, the support substrate and the curved reflector together defining a light aperture through which light produced by the light emitting semiconductor device passes, wherein the light emitting semiconductor device, the curved reflector, and the support substrate define a light emission module, the light source further including:
• a support structure;
• a plurality of first light emission modules arranged on the support structure and emitting light directed away from the support structure at a first angle;
• and
• a plurality of second light emission modules arranged on the support structure and emitting light directed away from the support structure at a second angle different from the first angle, the second light emission modules being interspersed among the first light emission modules.

A headlight for a vehicle, the headlight comprising:

• a support surface;
• and
• a plurality of light emission modules each including:
• a reflective cup including a planar portion and a parabolic portion joined together at a parabolic interface, an open end of the parabolic portion defining a light output opening, and
• a light emitting semiconductor die attached to the planar portion of the reflective cup and oriented to produce light directed toward the parabolic portion of the reflective cup,
• wherein the light emission modules are arranged on the support surface with the planar portion of each reflective cup parallel to the support surface and the light output openings of the reflective cups and arranged such that the plurality of light emission modules produce a cumulative light beam and include:
• low beam light emission modules that produce light directed at a low beam angle relative to an axis of the interface;
• and
• high beam light emission modules that produce light directed at a high beam angle relative to the axis of the interface, the high beam angle being smaller than the low beam angle.

A solid-state light source including:

• a solid-state light emitting device;
• and
• a reflector including a generally planar side and a generally concave curved side facing the generally planar side, the solid-state light emitting device supported by the generally planar side, which provides primary heat sinking for the light emitting device, and emitting light generally directed toward the concave curved side, the reflector further including an opening defined by edges of the generally planar side and the generally concave curved side, toward which opening the generally planar side and the generally concave curved side cooperatively direct light produced by the solid-state light emitting device;
• and
• a translucent or transparent filling material filling the reflector and having an light-transmissive surface disposed at the reflector opening which translucent or transparent filling material is arranged at a non-perpendicular angle to the generally planar side to refractively tilt the light.

A method for manufacturing a light source, the method including:

• securing a light emitting semiconductor die to a reflective planar surface;
• heat sinking the light emitting semiconductor via the planar surface;
• applying an encapsulant over the light emitting semiconductor die to seal the die, the applying defining an encapsulant surface having an aperture side and a curved side;
• and
• applying a reflective layer to the curved side of the encapsulant.