Glass Light Pipe and Polymeric Shaping for Uniform LED Mixing
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Solution Overview
Problem
Existing light-mixing systems for high-power light sources, such as LEDs, face challenges in producing uniformly mixed light and reducing source imaging, with limited efficiency and sub-par illumination characteristics.
Innovation Solution
An optical system comprising a glass light pipe and a polymeric light-shaping element with microlenses, where the polymeric element is optically coupled to the glass light pipe's output surface, and a projection lens is used to receive light, allowing for efficient light mixing and beam modulation through reflection and texturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If textured surfaces are used to spread light from a light source, then light distribution is improved, but efficiency and illumination characteristics deteriorate
Solution Approach 1:
The patent introduces a glass light pipe as an intermediary component between the light source and the textured surface. The light pipe guides and conditions the light before it reaches the light-shaping element, improving overall system efficiency while maintaining good light distribution. This mediator allows the system to achieve both uniform illumination and high efficiency by separating the light guidance function from the light shaping function.
Solution Approach 2:
The patent employs a composite structure combining glass light pipe material with polymeric light-shaping element material. This composite approach allows optimization of each component for its specific function - the glass light pipe for efficient light transmission and the polymeric element for effective light shaping - thereby resolving the contradiction between efficiency and illumination quality.
2Adaptability or versatility
If light from multiple sources is mixed, then color variety is improved, but uniformity of mixed light deteriorates
Solution Approach 1:
The patent segments the light mixing process into distinct stages: individual light sources first pass through separate glass light pipes that condition and homogenize each source's output, then the pre-conditioned light from multiple sources is combined. This segmentation allows each source to be independently optimized while achieving uniform mixed light output, resolving the contradiction between color variety and uniformity.
Solution Approach 2:
The patent applies preliminary light conditioning through the glass light pipe before the light enters the mixing and shaping stage. By pre-homogenizing each light source's output and removing source imaging effects beforehand, the subsequent mixing process produces uniformly combined light with excellent color mixing capability, eliminating the trade-off between color variety and uniformity.
3Illumination intensity
If source imaging is reduced, then light uniformity is improved, but light intensity concentration deteriorates
Solution Approach 1:
The patent applies local quality modification through the textured surface on the light-shaping element, which selectively scatters and redistributes light at the output stage. This localized action occurs only at the exit surface, maintaining uniform light distribution while preserving overall light intensity through the use of high-reflection materials and optimized light pipe geometry that minimize losses throughout the 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 system effectively mixes light from multiple sources, including LEDs of different colors, achieving uniform luminosity and improved beam characteristics, such as adjustable divergence and cross-sectional shape, enhancing light distribution and reducing sharpness of the output pattern.
Implementation Method 1
a glass light pipe having an input surface for receiving light from a light source and a polymeric light-shaping element having an input surface that is optically coupled to the output surface of the glass light pipe to receive at least a portion of the light exiting the glass light pipe
Implementation Method 2
The light-shaping element includes a plurality of microlenses on any of its input and/or output surface
Implementation Method 3
In some cases, the textured surface can include a plurality of surface undulations characterized by heights in a range of about 0.01 mm to about 0.25 mm
Implementation Method 4
A projection lens is optically coupled to the output surface of the polymeric light-shaping element to receive light thereform
Data Source
AI summary
An optical system is disclosed, which comprises a glass light pipe having an input surface for receiving light from a light source and an output surface through which light exits the light pipe, and a polymeric light pipe optically coupled at its input surface to the output surface of the glass light pipe to receive at least a portion of the light exiting the glass light pipe, said polymeric light pipe having a textured output surface. A plurality of microlenses is optically coupled to said textured surface of the polymeric light pipe, and a projection lens is optically coupled to the output surface of the polymeric light pipe to receive light therefrom.