Angled Base Collimator for Light Direction Control
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Solution Overview
Problem
Existing collimator designs face energy loss and inefficiency due to tilting or the use of additional optics, and they are costly and time-consuming to manufacture, especially when directing light at different angles.
Innovation Solution
A collimator with a parabolic or cone-shaped main body and an angled base that can be adjusted to control the emission angle without additional optics, using a single mold to produce both angled and non-angled collimators, minimizing light escape and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the collimator is tilted relative to the light source to change emission angle, then the light emission direction is adjusted, but an open space or gap is created between the light source and the base of the collimator causing light to escape and energy loss
Solution Approach 1:
The patent introduces a new dimensional parameter - the base angle θ1 of the collimator base relative to the mounting board. By varying this base angle, the optical axis orientation changes, allowing light emission in different directions without tilting the entire collimator body, thus preventing gap formation and light escape.
Solution Approach 2:
The patent changes the geometric parameter of the base angle θ1 to control the emission direction. This parameter change allows the optical axis to be oriented at different angles while maintaining full contact between the collimator base and mounting board, eliminating the energy loss associated with gaps.
2Adaptability or versatility
If a prismatic optic is placed on top of the collimator to angle the light, then the light direction is controlled, but Fresnel losses of 8-10% occur and additional parts are required
Solution Approach 1:
The patent merges the light direction control function directly into the collimator structure by incorporating an angled base, eliminating the need for separate prismatic optics. This integration removes the additional optical surfaces that cause Fresnel losses while maintaining the ability to control light direction through the base angle θ1.
Solution Approach 2:
The collimator base serves multiple functions: it provides structural support, ensures full contact with the mounting board to prevent light escape, and controls the emission angle through its angle θ1. This multi-functionality replaces the need for separate prismatic optics.
3Measurement precision
If different prismatic optics are selected for different light angles, then precise angle control is achieved, but cost and manufacturing time increase
Solution Approach 1:
The patent creates a universal collimator design where a single base structure with variable angle θ1 can produce multiple emission angles. This eliminates the need to manufacture and inventory multiple specialized prismatic optics for different angles, significantly reducing manufacturing time and cost while maintaining precise angle control.
Solution Approach 2:
Instead of manufacturing different physical components for different angles, the patent uses parameter changes in the base angle θ1 to achieve different emission directions. This single-parameter approach simplifies manufacturing to a single process that can produce any required angle, improving productivity.
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
This design minimizes light loss and reduces manufacturing costs and time by allowing for adjustable emission angles without extra optics, using a single mold to produce collimators with either parallel or angled bases, enhancing both optical efficiency and manufacturing efficiency.
Implementation Method 1
The collimator has a characteristic called total internal reflectance (or 'TIR'), which means that the collimator refracts the rays of light and emits them in a direction generally parallel to the optical axis
Implementation Method 2
the collimator refracts the rays of light and emits them in a direction generally parallel to the optical axis
Implementation Method 3
Light emitted from the light source enters the collimator aperture and the collimator refracts and emits the light in a direction generally parallel to the optical axis
Data Source
AI summary
Collimators and methods of making collimators. According to certain embodiments a collimator may be used with a light source, where the light source emits light along a light source axis. The base of the collimator may be angled such that the collimator refracts the light in a direction that is angled relative to the light source axis. There may also be provided methods for making a collimator. According to one method, a mold is first provided that produces an uncut collimator having an extended portion. The uncut collimator may be cut at an angle to produce a collimator with an angled base. In another method, there may be a mold with a base cavity, and a wedge may be inserted in the base cavity. The wedge forms a collimator with an angled base.