Hybrid Lens for Solid State Light Source

Solution Overview

Problem

Current solid state light source devices using polymer optics for flame retardancy suffer from reduced light output and yellowing issues due to the use of filled polycarbonate materials that meet UL94, Class V-O requirements, which are less transparent and degrade faster than unfilled materials.

Innovation Solution

A hybrid lens is designed with a flame retardant material on the exterior and a non-flame retardant material closer to the light source, allowing for maximum light output while meeting UL safety requirements, using materials like glass and unfilled polymers such as polycarbonate and polymethylmethacrylate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If filled polycarbonate material is used to meet UL94, Class V-O flame retardant requirements, then flame safety is improved, but light output is reduced by 5-10 percent and yellowing occurs faster

Engineering Contradiction:

Improveflame safetyVSAvoidlight output

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The lens is divided into two distinct components: a first component made of flame-retardant material (meeting UL94, Class V-O requirements) and a second component made of non-flame-retardant material (optimized for optical performance). This segmentation allows each component to fulfill its specific function without compromise - the exterior component provides flame safety while the interior component maximizes light output and resistance to yellowing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the lens assembly are assigned different material properties based on their functional requirements. The exterior surface (first component) uses flame-retardant material for safety compliance, while the interior region (second component) uses high-transparency material for optimal light transmission. This local differentiation resolves the contradiction by matching material properties to spatial locations.

Inventive Principle:

Principle #3Local quality

2Reliability

If filled polycarbonate material is used to meet UL94, Class V-O flame retardant requirements, then flame safety is improved, but the material turns yellow much faster due to blue component of spectrum

Engineering Contradiction:

Improveflame safetyVSAvoidcolor stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The lens is divided into two distinct components: a first component made of flame-retardant material (meeting UL94, Class V-O requirements) and a second component made of non-flame-retardant material (optimized for optical performance). This segmentation allows each component to fulfill its specific function without compromise - the exterior component provides flame safety while the interior component maximizes light output and resistance to yellowing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the lens assembly are assigned different material properties based on their functional requirements. The exterior surface (first component) uses flame-retardant material for safety compliance, while the interior region (second component) uses high-transparency material for optimal light transmission and color stability.

Inventive Principle:

Principle #3Local quality

3Reliability

If glass optic is used to meet UL requirements, then flame retardant requirements are fulfilled, but manufacturing precision and cost-effectiveness are compromised

Engineering Contradiction:

Improveflame retardant complianceVSAvoidoptical precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The lens is divided into two distinct components: a first component made of flame-retardant material (meeting UL94, Class V-O requirements) and a second component made of non-flame-retardant material (optimized for optical performance). This segmentation allows each component to fulfill its specific function without compromise - the exterior component provides flame safety while the interior component maximizes light output and resistance to yellowing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lens assembly uses a composite structure combining two different material types - flame-retardant material for the exterior component and high-transparency polymer material for the interior component. This composite approach allows the system to achieve properties that neither material could provide alone, specifically meeting both flame safety requirements and optical performance requirements simultaneously.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20140254175A1Hybrid lens for solid state light source device

Publication Date: 2014.09.11 ABL IP HLDG LLC

AI summary

A hybrid lens for a solid state light source device is provided. The hybrid lens includes a first component and a second component. The first component has a first side and a second side oppositely disposed thereto. The first side is positioned facing a solid state light source. The second component is attached to the first side of the first component. The first component includes a flame retardant material, such as a glass or a filled polymer. The second component includes a non-flame retardant material, such as an unfilled polymer.