Large-Angle LED Lens Curved Surface Design
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Solution Overview
Problem
Existing LED light source modules have limited light beam angles of approximately 110°~120°, resulting in inefficient light energy utilization, and there is a need to optimize the design of the incident and exit surfaces of the lens to enhance the emission angle.
Innovation Solution
A large-angle lens with a shell-shaped body featuring a transparent concave incident surface and a transparent convex exit surface, where the thicknesses and geometries are optimized to achieve a light-emitting angle greater than 130°, minimizing total reflection and maximizing light utilization efficiency to 90%, and integrated with a mounting structure for secure encapsulation of the LED device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a conventional LED light source is used, then the structure is simple, but the light beam angle is limited to 110°~120° and light energy utilization efficiency is low
Solution Approach 1:
The patent applies curved surface design to the lens, with a convex exit surface and concave incident surface. The exit surface has a specific convex height h1 and the incident surface has a concave depth h2, creating spherical curvature that effectively expands the light beam angle to 130° or more while maintaining structural feasibility
Solution Approach 2:
The patent optimizes specific geometric parameters of the lens to achieve the desired light distribution. The thickness ratio d1/d2 is controlled within 1.1-1.5, the convex height h1 and concave depth h2 satisfy h1>5d2 and h2>4d2, and the distance between LED and lens is set to 0.5-2mm, transforming the light beam angle from 110°~120° to 130° or more
2Loss of energy
If the lens thickness is increased to improve light extraction, then light utilization improves, but total internal reflection increases and light loss occurs
Solution Approach 1:
The curved surfaces of the lens (convex exit surface with height h1 and concave incident surface with depth h2) are designed to minimize total internal reflection. The specific curvature radii and surface profiles guide light rays to exit the lens more efficiently, reducing energy loss while maintaining effective light extraction
Solution Approach 2:
The patent controls the thickness ratio d1/d2 within 1.1-1.5 and sets specific relationships between convex height h1>5d2 and concave depth h2>4d2. These parameter optimizations balance light extraction efficiency with minimizing total internal reflection losses, achieving over 90% light utilization
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 large-angle lens significantly increases the light-emitting angle, enhancing lighting evenness and efficiency, while protecting the LED device from external influences, thus prolonging its service life and reducing the number of modules required for a given area, thereby lowering production and labor costs.
Implementation Method 1
The main body has an incident surface on the inner side of the main body and an exit surface on the outer side of the main body. Both of the incident surface and the exit surface are provided symmetrically about the central axis of the main body, the incident surface being a transparent concave surface, and the exit surface being a transparent convex surface.
Implementation Method 2
minimizing total reflection and maximizing light utilization efficiency to 90%
Data Source
Figure 1~2
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AI summary
Disclosed is a large-angle LED lens including a main body which has an incident surface on the inner side of the main body and an exit surface on the outer side thereof. The surfaces are provided symmetrically about the central axis of the main body. The incident and exit surfaces are transparent concave and convex surfaces, respectively. The maximum thickness d1 of the main body at the lower part and the minimum thickness d2 thereof at the top satisfy the relation: 4<d1/d2<6; the concave depth h1 of the concave surface and the thickness d2 satisfy the relation: h1>4*d2; and the convex height h2 of the convex surface and the thickness d2 satisfy the relation: h2>5*d2. With the disclosure, the light-emitting angle is increased while maximizing the utilization of the light. A large-angle emission LED light source module is also disclosed herein.