Dual Lens Array Optical Integrator for Uniform LED Beam Control
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Solution Overview
Problem
Existing optical systems for LED light sources require additional optics to control output beam angles and achieve good light mixing, leading to increased size, weight, and cost due to the need for collimated light input to prevent color artefacts.
Innovation Solution
An optical output system comprising two arrays of convex lenses with a narrow air gap between them, functioning as a modified Kohler integrator, allowing for effective light mixing and beam control without pre-collimation, thereby reducing glare and enabling low-cost, low-weight designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional optics are used to control output beam angles and achieve good light mixing, then light mixing quality improves, but device size, weight, and cost increase
Solution Approach 1:
The patent combines two lens arrays into a single integrated optical element with a narrow air gap between them, merging the functions of beam control and light mixing into one compact structure. This eliminates the need for separate additional optics while maintaining effective light mixing and beam angle control.
Solution Approach 2:
The design nests one lens array within close proximity to another lens array, with the narrow air gap (less than 10% of the maximum thickness) creating a compact nested structure. This allows multiple optical functions to be achieved within a reduced overall form factor.
2Measurement precision
If additional optics are used to control output beam angles, then beam control precision improves, but device weight increases
Solution Approach 1:
The patent merges beam control and light mixing functions into a single integrated optical element consisting of two lens arrays with a narrow air gap, eliminating the need for separate heavy optical components while maintaining precise beam angle control.
Solution Approach 2:
The patent changes the structural parameter by using a narrow air gap (less than 10% of the maximum thickness) between lens arrays, which enables precise beam control with reduced material usage and lower weight compared to traditional separate optical components.
3Stability of the object's composition
If additional optics are used to prevent color artefacts, then color mixing uniformity improves, but device volume increases
Solution Approach 1:
The patent nests two lens arrays in close proximity with a narrow air gap, creating a compact integrated structure that provides effective color mixing and prevents color artefacts without requiring additional volume for separate optical components.
Solution Approach 2:
The patent combines color mixing and beam control functions into a single integrated optical element, eliminating the need for separate additional optics while maintaining uniform color mixing and preventing color artefacts in the output beam.
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 system provides a uniform wide beam output with good light mixing and attractive appearance, reducing glare and artefacts, while maintaining a compact and cost-effective design by using a narrow air gap to manage light distribution effectively.
Implementation Method 1
a first array of lenses, comprising convex lenses facing the light source location
Implementation Method 2
a second array of lenses, on the opposite side of the first array of lenses to the light source location, and comprising convex lenses facing away from the light source location
Implementation Method 3
there is an air gap between the first and second arrays of lenses, wherein the thickness of the air gap is less than 10% of the maximum thickness between the outer surfaces of the first and second arrays of lenses
Data Source
AI summary
An optical output system for an LED light source has a pair of lens arrays (40, 42) with a narrow air gap (48) between the lens arrays (40, 42). The optical system provides an optical integration function for light mixing, and the air gap (48) enables a uniform wide-beam output to be provided even for incident light from a wide range of angles, for example as received from a non-collimated light source.