Co-molded Silicone Compound Lens for LED Beam Control
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Solution Overview
Problem
Existing LED compound lens systems are mechanically and optically complex, inflexible, and costly, lacking the ability to easily modify their optical properties without significant mechanical adjustments.
Innovation Solution
A compound lens system comprising co-molded optical grade silicone lens elements, including a plano-concave, hemispherical, bi-concave frusto-conical, and bi-convex aspheric lenses, which are optically coupled to reduce wavefront error and mechanical path differences, allowing for integration into a single molded package with optional thermoplastic holding members for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual lenses are physically mounted in the illumination path to achieve desired focus and beam control, then optical functionality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
Multiple separate lens elements are merged into a single integrated compound lens structure. The patent combines multiple lens elements with different optical functions (collimating lens, focusing lens, beam shaping lens) into one monolithic component, eliminating the need for separate mechanical mountings and alignments while preserving all optical functionalities.
Solution Approach 2:
The compound lens performs multiple optical functions simultaneously within a single element. It provides collimation, focusing, beam spreading, and shape control all in one component, making the system more versatile without requiring additional separate lenses or mechanical assemblies.
2Adaptability or versatility
If conventional compound lens systems are used to control LED light emission, then beam shaping capability is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
Multiple lens elements are combined into a single molded compound lens, eliminating the need for separate manufacturing and assembly processes. This integration significantly reduces manufacturing cost and assembly time while maintaining advanced beam shaping capabilities.
Solution Approach 2:
The patent utilizes variations in refractive index and lens surface curvatures across different zones of the compound lens to achieve complex beam shaping. By changing optical parameters within the single integrated structure, multiple optical functions are accomplished without requiring multiple separate components.
3Manufacturing precision
If multiple individual lenses are mounted and aligned mechanically, then optical alignment precision is improved, but device complexity and cost increase
Solution Approach 1:
Multiple lens elements are merged into a single integrated compound lens, eliminating all mechanical alignment requirements. The optical precision is achieved through precision molding of the entire compound lens as one piece, removing the need for separate mountings and alignments of individual lenses.
4Manufacturing precision
If existing compound lens systems are used, then focus control is improved, but flexibility and tunability worsen
Solution Approach 1:
The compound lens incorporates variable optical parameters including different refractive indices in different zones, varying surface curvatures, and adjustable lens element configurations. These parameter variations enable both precise focus control and flexibility to adjust beam characteristics for different applications.
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 solution provides a cost-effective, durable, and tunable LED lens system capable of producing highly controlled angled divergent beams with uniform intensity profiles, reducing assembly time and cost, and withstanding harsh environments.
Implementation Method 1
The first and second lens elements are in optical alignment along a common optical axis with each other and an LED light source. The LED light source is in sequential optical communication with the first and second lens elements.
Data Source
AI summary
A compound lens and a related method of manufacture are provided. The compound lens includes a first lens element and a second lens element such that a light emitting surface of the first lens element is integrally joined to a light receiving surface of the second lens element, the first and second lens element being in optical alignment with each other. The first and second lens element are molded from optical grade silicone and can achieve complex illumination objectives not possible with single lens constructions. The method of manufacture includes injecting a silicone resin molding compound into a mold cavity having the desired shape of the compound lens. The method of manufacture can include over-molding a lens holding member onto the compound lens and adding electro-optically active particles to a surface of the compound lens or to the silicone resin forming the compound lens.