Monolithic LED Optical Element with Knurled TIR for Glare Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED lighting systems face issues with efficiency and visual comfort due to internal reflections and material impurities causing light scattering beyond desired angles, necessitating additional anti-dazzling screens that reduce efficiency.
Innovation Solution
An LED lighting system design featuring a monolithic lens and hollow structure with a knurled outer surface that utilizes total internal reflection (TIR) to redirect scattered light within desired angles, achieving high optical efficiency without anti-dazzling screens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a lens is used to collect and control 100% of the emitted light flux, then the light direction control is improved, but internal reflections and material impurities cause light scattering above the required angular limit creating dazzling
Solution Approach 1:
The optical element is divided into two functional zones: a lens portion for collecting and directing light, and a black anti-dazzling screen portion for absorbing scattered light. This segmentation allows each zone to perform its specific function optimally without interfering with the other.
Solution Approach 2:
The black anti-dazzling screen converts the harmful scattered light (which would cause dazzling) into beneficial absorbed energy. By strategically placing this absorbing element, the patent transforms what was previously a waste into a functional component that improves visual comfort.
2Object-affected harmful factors
If a black anti-dazzling screen is added to eliminate dazzling, then visual comfort is improved, but the efficiency of the lighting device is reduced and an additional component is required
Solution Approach 1:
The lens and anti-dazzling screen are merged into a single monolithic optical element made of transparent material with a black portion. This integration eliminates the need for separate components and assembly steps while maintaining both light direction control and anti-dazzling functions.
Solution Approach 2:
The patent changes the optical parameters of the material by creating a monolithic structure with varying transparency - transparent regions for light transmission and black regions for light absorption. This parameter variation within a single component achieves both functions efficiently.
3Object-affected harmful factors
If a black anti-dazzling screen is added to eliminate dazzling, then visual comfort is improved, but the device complexity increases due to additional component manufacturing and assembly
Solution Approach 1:
The lens and anti-dazzling screen are merged into a single monolithic optical element made of transparent material with a black portion. This integration eliminates the need for separate components and assembly steps while maintaining both light direction control and anti-dazzling functions.
Solution Approach 2:
The monolithic optical element performs multiple functions simultaneously: light collection, light direction control, and anti-dazzling. This multi-functionality reduces the overall device complexity by eliminating the need for separate specialized components.
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 achieves 95% light emission efficiency within 45-60 degrees, providing high visual comfort and optical efficiency while maintaining compactness and simplicity.
Implementation Method 1
a lens associated with the LED placed close to the same and capable of collecting and controlling 100% of the emitted light flux. Such lenses direct almost all of the light within the desired angles
Implementation Method 2
The outer structure is in the form of a hollow solid, typically with a quadrangular or hexagonal base, an appropriately designed cross section, and with the outer lateral surface which is knurled at 90°. By virtue of this particular design of the outer surface, by the effect of total internal reflection (TIR), the light exiting the lens is retroreflected by catadioptric effect and directed, thanks to the appropriate cross section of the hollow outer structure, within the useful angles.
Data Source
Figure 1~2
Figure 3~7
Figure 8~10
AI summary
An LED lighting system (1) comprises a support base (2), a printed circuit board (3) provided with a plurality of LEDs (4), and a plurality of optical elements (5) aligned with respective LEDs (4) along respective axes (A); each optical element (5) extends along and around the respective axis (A) and comprises a central lens (15) arranged along the axis (A) and made of a transparent material, and a lateral hollow structure (16), substantially cup-shaped and positioned around the axis A and the lens (15); the structure (16) is also made of a transparent material and has a prismatic outer lateral surface (27) provided with a series of longitudinal prismatic ridges (28) arranged side by side and separated by grooves (29).