Faceted Non-Imaging Lens for Uniform LED Illumination
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Solution Overview
Problem
Existing optical lenses for light-emitting diodes (LEDs) face challenges in achieving uniform light distribution and are costly to manufacture, with limitations in reducing facula and shadow formation.
Innovation Solution
A non-imaging optical lens with a concave region formed by a continuous curved surface composed of multiple facets, arranged in rows and columns with gradually increasing or decreasing slopes, which deranges and scatters incident light to achieve wide diffusion and uniform light distribution, while being easier and less costly to manufacture than smooth aspheric surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a smooth aspheric surface is used to achieve uniform light distribution, then light diffusion effect is improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The continuous aspheric surface is segmented into multiple discrete facets arranged in concentric rings. Each facet acts as a small planar surface with a specific tilt angle, collectively approximating the desired aspheric curvature. This segmentation enables manufacturing using conventional techniques while achieving similar optical diffusion effects.
Solution Approach 2:
The patent replaces expensive precision-machined smooth aspheric surfaces with cheaper faceted structures that can be manufactured using standard molding or machining processes. The faceted design accepts slight optical compromises but achieves sufficient uniformity at much lower cost.
2Reliability
If a conventional optical lens is used for light convergence, then focusing ability is improved, but facula and shadow effects worsen
Solution Approach 1:
Different zones of the lens have different facet orientations and densities. The faceted structure creates localized refraction patterns that distribute light more evenly across the output surface, preventing concentrated hot spots (facula) and shadow regions while maintaining overall convergence.
Solution Approach 2:
The patent transitions from conventional single-surface lenses to a multi-faceted structure with facets arranged in multiple concentric rings at different radii and angles. This multi-dimensional arrangement of facets creates complex refraction paths that eliminate facula and shadow effects.
3Illumination intensity
If a concave diffusing structure is added to achieve uniform light, then light diffusion is improved, but device complexity increases
Solution Approach 1:
The patent combines the diffusing function with the primary lens structure by integrating facets directly into the lens body. The faceted surface serves both as the optical interface and the diffusing element, eliminating the need for separate diffusing components or complex multi-element assemblies.
Solution Approach 2:
The faceted lens structure performs multiple functions simultaneously: it provides light convergence through its overall curvature, creates uniform diffusion through facet orientations, and maintains structural integrity as a single piece. This multi-functionality reduces device complexity compared to multi-component systems.
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 lens achieves effective light diffusion and uniformity, reducing facula and shadow effects, and is more cost-effective to produce due to its facet-based design, enhancing the performance of light-emitting modules.
Implementation Method 1
the light is then refracted at the surface with wide diffusion angle, which thus achieves effects of diffusion and uniform light
Data Source
AI summary
The present invention relates to a non-imaging optical lens and a light-emitting module having the same. The lens includes a concave region having a continuous curved optical surface formed by a plurality of facets spliced together. The continuous curved optical surface faces the light-emitting device. The curved surface consists of an array in at least three rows of the facets and at least three columns of the facets.