LED Array Light Collection With Compact Color Homogenization
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Solution Overview
Problem
Existing automated luminaires face challenges in adequately mixing light from multi-color LED arrays with increased distances between same-color LEDs, leading to inadequate color mixing, spill light, and reduced efficiency due to the use of long light integrator optics or multiple fly-eye lens arrays.
Innovation Solution
Combining a light integrator optic with a homogenizer, such as fly-eye lens arrays, to enhance light mixing and homogenization, while reducing the size and improving efficiency of the luminaire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a long light integrator optic is used to mix light from multi-color LED arrays, then color mixing quality is improved, but luminaire size increases and efficiency decreases
Solution Approach 1:
The light mixing system is divided into multiple segments: a light integrator optic that receives light from LEDs and performs initial mixing, followed by multiple fly-eye lens arrays that perform additional mixing stages. This segmentation allows achieving good color mixing in a more compact configuration compared to a single long integrator optic.
Solution Approach 2:
The patent transitions from a single-dimensional long integrator optic to a multi-dimensional arrangement using multiple fly-eye lens arrays positioned at different locations. The light undergoes mixing in multiple spatial dimensions and stages, achieving thorough color mixing while reducing the overall luminaire size.
2Manufacturing precision
If multiple fly-eye lens arrays are used to mix light from multi-color LED arrays, then color mixing quality is improved, but device complexity increases
Solution Approach 1:
Each fly-eye lens array serves multiple functions: it acts as a homogenizer for light distribution, a mixing element for color integration, and an optical relay component. This multi-functionality reduces the need for separate dedicated components, thereby managing device complexity while achieving superior color mixing.
Solution Approach 2:
The patent combines the functions of light homogenization and color mixing into the same fly-eye lens arrays. By merging these functions into unified optical elements rather than using separate components, the system achieves improved color mixing while controlling overall device complexity.
3Quantity of substance
If increased distances between same-color LEDs are used in LED arrays, then LED density is improved, but light mixing effectiveness decreases
Solution Approach 1:
The fly-eye lens arrays act as intermediary optical elements that facilitate light mixing between LEDs that are spaced further apart. These intermediaries collect light from individual LEDs and redistribute it in a manner that achieves effective color mixing despite increased distances between same-color LEDs, thereby maintaining high LED density.
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
Achieves a suitably homogeneous and well-mixed output beam from multi-color LED arrays with improved efficiency and reduced size compared to systems using only light integrator optics or fly-eye lens arrays alone.
Implementation Method 1
a light integrator optic to receive the plurality of light beams and to internally reflect the light beams to generate a plurality of at least partially-homogenized light beams
Implementation Method 2
a first lens array having a first plurality of collimating lenslets corresponding to the plurality of LED emitters, where the first lens array is optically coupled to the plurality of LED emitters and configured to emit a plurality of light beams corresponding to the plurality of LED emitters, each of the light beams including partially collimated light rays
Implementation Method 3
a converging lens optically coupled to the homogenizer. The homogenizer and the converging lens illuminate a gate with the plurality of light beams from the light integrator optic
Data Source
AI summary
An LED light engine includes a plurality of LED emitters; a first lens array having a plurality of collimating lenslets corresponding to the plurality of LED emitters, where the first lens array is optically coupled to the plurality of LED emitters and configured to emit a plurality of light beams corresponding to the plurality of LED emitters, each of the light beams including partially collimated light rays; a light integrator optic to receive the plurality of light beams and to internally reflect the light beams to generate a plurality of at least partially-homogenized light beams; a homogenizer optically coupled to the light integrator optic and configured to receive the plurality of at least partially-homogenized light beams from the light integrator optic; and a converging lens optically coupled to the homogenizer. The homogenizer and the converging lens illuminate a gate with the plurality of light beams from the light integrator optic.