LED Lamp Optical Element Spacing for Light Distribution
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Solution Overview
Problem
Current LED lighting systems face challenges in achieving high efficiency, high output, and optimal color rendering index (CRI) while maintaining a desirable form factor and energy efficiency, particularly in meeting standards set by initiatives like the L Prize.
Innovation Solution
The development of a high-efficiency solid-state lamp incorporating an LED assembly with an optical element that includes a primary exit surface spaced from the LED assembly to enhance light distribution, combined with a power supply and heat management systems, utilizing phosphor or quantum dots for wavelength conversion to achieve warm white light with a high CRI and specific correlated color temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LED dies are mounted within an LED package with protective housing and heat sink, then reliability and heat management are improved, but device complexity increases
Solution Approach 1:
The patent combines the protective housing and heat sink into a single integrated component structure. The housing serves dual functions as both protective enclosure and thermal management element, eliminating the need for separate components and reducing overall device complexity while maintaining reliability.
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: mechanical protection of LED dies, thermal conduction away from the LEDs, and structural support for optical elements. This multi-functionality reduces the total number of components needed in the system.
2Volume of moving object
If optical elements are placed close to LED modules, then form factor is reduced, but light distribution and color mixing are compromised
Solution Approach 1:
The patent extends the optical path in the radial direction by positioning the primary exit surface at a distance from the LED assembly. This creates a longer light path through the optical element, improving color mixing and light distribution quality without significantly increasing the overall fixture volume.
Solution Approach 2:
The optical element uses curved surfaces to redirect and distribute light from the LED assembly. The curved geometry allows light to travel longer paths and mix colors more effectively before exiting through the primary exit surface, achieving good illumination quality in a compact form factor.
3Productivity
If multiple LED dies are combined in an array, then light output is increased, but achieving high CRI and efficiency becomes more difficult
Solution Approach 1:
The patent uses different LED dies with specific wavelength emissions (blue, cyan, green, yellow-green, yellow, orange, red) positioned in specific locations within the array. Each wavelength region is optimized for its specific function, and the optical element redirects light from different regions to achieve uniform color mixing and high CRI while maintaining overall system efficiency.
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 solution results in an LED lamp with a light output of at least 1200 lumens, efficiency of 150-300 lumens per watt, and a CRI of 90 or higher, meeting the requirements for high efficiency and color rendering standards, including those set by the L Prize category.
Implementation Method 1
a large percentage of light from the LED assembly strikes curved walls of the optical element at an oblique angle and exits the fixture through the primary exit surface of the optical element
Implementation Method 2
utilizing phosphor or quantum dots for wavelength conversion to achieve warm white light with a high CRI and specific correlated color temperature
Data Source
AI summary
A high-efficiency LED lamp is disclosed. Embodiments of the present invention provide a high-efficiency, high output solid-state lamp. The lamp includes an LED assembly, and an optical element or diffuser disposed to receive light from the LED assembly. The optical element includes a primary exit surface, wherein the primary exit surface is at least about 1.5 inches from the LED assembly. In example embodiments, the optical element is roughly cylindrical in shape, but can take other shapes and be made from various materials. An LED lamp according to some embodiments of the invention has an efficiency of at least about 150 lumens per watt. In some embodiments, the lamp has a light output of at least 1200 lumens. In some embodiments, the LED lamp produces light with a color rendering index (CRI) of at least 90 and a warm white color.