3D-Printed Internal Cavity Lens for Lumen Maintenance

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Solution Overview

Problem

LED lighting systems face challenges with lumen depreciation due to dust and dirt accumulation on refractive optics with contoured external surfaces, leading to reduced effectiveness in achieving target light levels and distributions, and traditional lens manufacturing methods struggle with complex beam patterns and assembly issues.

Innovation Solution

A 3D printed internal cavity lens with planar external surfaces and nonplanar internal refractive surfaces is designed using light-energy mapping techniques, reducing dirt accumulation and facilitating efficient beam distribution and assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If refractive optics with contoured external surfaces are used to achieve target light distribution, then beam shaping capability is improved, but lumen depreciation occurs due to dust and dirt accumulation

Engineering Contradiction:

Improvebeam distribution capabilityVSAvoidlumen maintenance

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent extracts the refractive function from the external surface and relocates it to an internal cavity. The external surface becomes flat and smooth, eliminating dirt accumulation zones, while the internal nonplanar cavity surfaces perform the beam shaping function through refraction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of having the refractive surface on the outside of the lens, the patent inverts the design by placing the refractive cavity surfaces inside the lens structure. This inversion allows the external surface to be flat and cleanable while the internal surfaces handle optical manipulation.

Inventive Principle:

Principle #13The other way round (Inversion)

2Illumination intensity

If lenses with non-flat external surfaces are used to achieve target light distribution, then optical performance is improved, but assembly challenges increase

Engineering Contradiction:

Improvelight distribution effectivenessVSAvoidassembly ease

Core Design Contradiction:

Illumination intensityVSEase of operation

Solution Approach 1:

The patent separates the flat external surface from the complex refractive geometry by moving the refractive function to an internal cavity. This extraction allows the external surface to be simple and planar for easy assembly, while the internal cavity maintains the required optical performance.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If traditional lens manufacturing methods are used, then manufacturing simplicity is maintained, but complex beam patterns cannot be achieved

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidbeam pattern complexity

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent changes the manufacturing approach from traditional molding to 3D printing technology. This parameter change enables the production of complex internal cavity geometries with nonplanar refractive surfaces that cannot be achieved through conventional manufacturing methods.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces traditional mechanical molding processes with additive manufacturing (3D printing). This substitution allows for the creation of complex internal cavity structures with precise geometric control that are impossible to achieve with conventional subtractive or molding techniques.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The internal cavity lens maintains optical efficiency, reduces lumen depreciation, and simplifies assembly by using 3D printing to create complex geometries that achieve target illuminance uniformity and efficiency.

Implementation Method 1

The first internal nonplanar refractive surface and the second internal nonplanar refractive surface are configured to refract received light to yield emitted light having a target output parameter

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS20250334248A13D printed internal cavity lens for lighting applications

Publication Date: 2025.10.30 RENESSELAER POLYTECHNIC INST

AI summary

In an embodiment, there is provided an apparatus. The apparatus includes an optic configured for a selected illumination application. The optic includes a first lens structure and a second lens structure. The first lens structure includes a first planar external surface configured to receive incident light, and a first internal nonplanar refractive surface opposing the first planar external surface. The second lens structure includes a second planar external surface configured to emit output light, and a second internal nonplanar refractive surface opposing the second planar external surface. The second planar external surface opposes the first planar external surface. The first internal nonplanar refractive surface and the second internal nonplanar refractive surface define a cavity. The first internal nonplanar refractive surface, the second internal nonplanar refractive surface, and the cavity are positioned between the first planar external surface and the second planar external surface. The first internal nonplanar refractive surface and the second internal nonplanar refractive surface are configured to refract received light to yield emitted light having a target output parameter corresponding to the selected illumination application.