LED Lighting Element with Dome Lens and Projection Lens

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Solution Overview

Problem

Newer generation LED technology, with smaller LED packaging, results in reduced light output, requiring increased numbers of LEDs and higher current to achieve comparable illumination, which shortens battery life and leads to non-uniform light distribution.

Innovation Solution

Positioning LEDs within the focal length of a short focal length dome magnifier and a longer focal length projection lens, along with a heat sink and aperture to ensure uniform light distribution without increasing power input, and using a non-adhesive mounting for the dome lens to prevent fogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If newer generation smaller LED packaging is used, then LED efficiency is improved, but light output is reduced

Engineering Contradiction:

ImproveLED efficiencyVSAvoidlight output

Core Design Contradiction:

Use of energy by moving objectVSIllumination intensity

Solution Approach 1:

The patent divides the lighting system into multiple LEDs arranged in a specific geometric pattern rather than using a single large LED. This segmentation allows the system to maintain high efficiency with small LEDs while achieving the required total light output through proper optical design and arrangement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a hierarchical optical structure where a first lens is positioned close to the LED array and a second lens is positioned farther away, with the first lens focusing light from multiple LEDs and the second lens further directing the combined light. This nested optical system amplifies the light output from small efficient LEDs

Inventive Principle:

Principle #7Nested doll (Nesting)

2Illumination intensity

If the number of LEDs is increased to compensate for reduced size, then total light output is improved, but light distribution uniformity deteriorates

Engineering Contradiction:

Improvetotal light outputVSAvoidlight distribution uniformity

Core Design Contradiction:

Illumination intensityVSStability of the object's composition

Solution Approach 1:

The patent positions LEDs at specific locations (corners and center) of a rectangular array and uses a first lens with specific optical properties to focus light from each LED location. This localized optical control ensures that light from multiple LEDs combines uniformly, preventing the non-uniform distribution that would result from simply increasing LED count without proper optical design

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If current to LED is increased to boost brightness, then light output is improved, but battery life deteriorates

Engineering Contradiction:

ImprovebrightnessVSAvoidbattery life

Core Design Contradiction:

Illumination intensityVSDuration of action of moving object

Solution Approach 1:

The patent replaces the electrical approach of increasing current to boost brightness with an optical approach using lens systems. The first lens (close to LEDs) and second lens (farther away) work together to amplify and direct light optically, achieving increased brightness without increasing electrical power consumption, thereby preserving battery life

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If adhesive materials are used to mount dome lens, then lens positioning is improved, but lens fogging occurs due to out-gassing

Engineering Contradiction:

Improvelens positioningVSAvoidlens fogging

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent removes the adhesive material from the optical path between the dome lens and the LED array. By eliminating the adhesive, the source of out-gassing that causes lens fogging is removed. The lens positioning is maintained through alternative means that do not involve adhesive materials in the optical path

Inventive Principle:

Principle #2Taking out (Extraction)

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

This configuration enhances illumination output and uniformity while extending battery life by maintaining consistent power input and preventing lens fogging, resulting in a brighter, shadow-free light source.

Implementation Method 1

Positioning LEDs within the focal length of a short focal length dome magnifier and a longer focal length projection lens, such that the projection of the light from the LED (or LED array) is substantially uniform

Methodology Applied

Scientific EffectLight: Light

Implementation Method 2

a heat sink and aperture to ensure uniform light distribution without increasing power input

Methodology Applied

Scientific EffectHeat sink: Heat Sink

Data Source

PatentUS11060695B1LED lighting element and method of manufacturing same

Publication Date: 2021.07.13 DESIGNS FOR VISION INC

AI summary

A lighting element is disclosed that provides a projection of light forming a substantially uniform bright light on a surface a known distance from the lighting element. The lighting elements includes a dome lens that is removably positioned on a light source, such that the light source is retained at a location within a focal length of a projection lens and at or within a focal length of the dome lens. The dome lens magnifies the light outputted by the light source, such that the projected light is brighter than the light generated by the light source.