Inverted Frustum LED Lens for Adjustable Beam Distribution
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Solution Overview
Problem
Traditional LED light distribution systems, such as reflection cups or lenses, face challenges in achieving efficient directional light distribution due to their simple cone-shaped reflective surfaces, which limit their ability to effectively control light rays and achieve uniform illumination.
Innovation Solution
An LED spotlight with a lens of an inverted frustum structure, featuring a groove incident surface, a reflective surface, and an exit surface, where the incident surface includes a first and second incident portion and a transition section of arc structure, allowing for the adjustment of beam angles between 25 degrees to 120 degrees through precise refraction and reflection of light rays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple cone-shaped reflective surface is used, then the device complexity is reduced, but the directional light distribution efficiency deteriorates
Solution Approach 1:
The incident surface is divided into multiple functional zones: a first incident portion with a first slope angle, a second incident portion with a second slope angle, and a transition section with a gradient of slope angles. This segmentation allows each zone to control light rays in specific directions, achieving efficient directional light distribution while maintaining manufacturing feasibility.
Solution Approach 2:
Different portions of the incident surface are assigned different slope angles tailored to their specific functions. The first incident portion has a slope angle optimized for direct light transmission, the second incident portion has a slope angle optimized for reflecting light to the reflective surface, and the transition section has gradient slope angles to smoothly redirect light. This local optimization of surface properties enables precise control over light distribution patterns.
2Productivity
If a complex light distribution structure is adopted, then the directional light distribution efficiency is improved, but the device complexity increases
Solution Approach 1:
The lens integrates multiple functions into a single component: the incident surface with its multi-zone slope structure for light refraction and direction control, the reflective surface for light reflection, and the exit surface for light output. This merging of refraction, reflection, and direction control functions into one integrated lens reduces the number of separate components while achieving superior light distribution efficiency.
3Manufacturing precision
If a fixed beam angle is designed, then the manufacturing precision is simplified, but the adaptability deteriorates
Solution Approach 1:
The transition section of the incident surface features a gradient of slope angles that can be adjusted to change the beam angle. By modifying the slope angles in the transition section, the lens can adapt to different lighting requirements and achieve beam angles within a range from 25 degrees to 120 degrees, providing both precision control and versatility.
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 design enables efficient directional light distribution, enhancing optical efficiency, reducing light spots, and allowing for adjustable beam angles, thereby improving lighting quality and versatility.
Implementation Method 1
The first incident portion is provided to be substantially parallel to the LED light source board so as to refract the light emitted from the LED light source toward the exit surface
Implementation Method 2
The reflective surface is configured to reflect the coming light toward the exit surface
Data Source
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AI summary
Disclosed is an LED spotlight (100), comprising a lens (20), an LED light source board (10) and one or more LED light sources (12) arranged as point light sources. The lens (20) is arranged above the LED light source board (10), and the lens (20) is of an inverted frustum structure with a larger top and a smaller bottom. The bottom of the lens (20) is provided with an incident surface (21) substantially directly facing the LED light source (12). The top of the lens (20) forms an exit surface (23) substantially parallel to the LED light source board (10). The side face of the lens (20) forms a reflective surface (22). The incident surface (21) is of a groove structure recessed in the direction away from the LED light source (12), and the incident surface (21) comprises a first incident portion (211), a second incident portion (212) and a transition section (213) arranged between the first incident portion (211) and the second incident portion (212). The incident surface (21), the exit surface (23) and the reflective surface (22) form a light distribution structure, such that a beam angle can be adjusted within the range of 25 degrees to 120 degrees under the action of the first incident portion (211), the second incident portion (212) and the transition portion (213). Accordingly, the LED spotlight (100) has the advantage of achieving an efficient directional light distribution.