LED Lens Curved Reflecting Surface Reduces Light Loss

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Solution Overview

Problem

Existing LED light source lenses suffer from sharp reflecting surfaces that cause light to be misdirected and are prone to deformation, leading to potential damage and increased light loss due to total internal reflections, particularly in mass production.

Innovation Solution

The design includes a refracting surface extending from the upper part reflecting surface parallel to the central axis, with a central part having an inwardly inclined side surface that redirects light, and a lower part with an arch-shaped refracting surface of smaller diameter than the upper part, reducing light loss and enhancing manufacturing robustness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a sharp reflecting surface is used in the upper part of the lens, then light can be reflected efficiently, but light paths become erroneous and manufacturing deformation occurs

Engineering Contradiction:

Improvelight lossVSAvoidlight path accuracy

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent replaces the sharp reflecting surface with a curved reflecting surface in the upper part of the lens. This curvature allows light to be reflected smoothly along correct paths, preventing erroneous light propagation while maintaining manufacturing robustness against deformation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent applies different surface characteristics to different parts of the lens: the upper part has a curved reflecting surface for light reflection, the central part has an inclined surface for light redirection, and the lower part has a refracting surface. This local differentiation optimizes light control while preventing manufacturing issues.

Inventive Principle:

Principle #3Local quality

2Productivity

If the lower part refracting surface has a wider area, then more light can be emitted to the side surface, but variation in curvature increases causing more light confinement

Engineering Contradiction:

Improvelight emission efficiencyVSAvoidlight confinement loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent optimizes the curvature parameters of the lower part refracting surface to achieve an optimal balance between emission area and light confinement. By carefully controlling the curvature variation, the patent maximizes side surface light emission while minimizing energy loss due to confinement.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the lens structure is simplified for mass production, then manufacturing ease increases, but light path control precision decreases

Engineering Contradiction:

Improvemanufacturing robustnessVSAvoidlight path control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent divides the lens into three distinct parts (upper part with curved reflecting surface, central part with inclined surface, and lower part with refracting surface), each with specific functions. This segmentation allows for optimized light control in each zone while maintaining overall manufacturing simplicity through integral molding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple light control functions (reflection, redirection, and refraction) into a single integral lens structure that can be manufactured in one process. This merging maintains light path precision while greatly simplifying mass production compared to multi-component assemblies.

Inventive Principle:

Principle #5Merging (Combining)

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 efficiently directs light through the side surface, reducing erroneous paths and light loss, while improving the lens's durability and manufacturing feasibility by minimizing deformation risks.

Implementation Method 1

Light directly incident on the reflecting surface 12 of the upper part 10 is radiated from the focal point 50, is reflected from the reflecting surface 12 of the upper part 10

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

is refracted at the first refracting surface 14, and is emitted perpendicular to the central axis 40 of the lens

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 3

light directly incident on the second refracting surface 34 is radiated from the LED light source located at the focal point 50, is refracted by the second refracting surface 34, and is emitted perpendicular to the central axis 40 of the lens

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS7540635B2LED light source lens having upper, central and lower parts

Publication Date: 2009.06.02 SAMSUNG ELECTRONICS CO LTD

AI summary

Disclosed herein is a Light Emitting Diode (LED) light source lens for emitting light in a lateral direction. The LED source lens includes an upper part, an upper part and a central part. The upper part includes an upper part reflecting surface bent symmetrically with respect to the central axis of the lens, and an upper part refracting surface extended from the end of the upper part reflecting surface parallel with the central axis. The central part includes a side surface extended from the lower end of the upper part refracting surface and bend inwards, and refracts or reflects light through the side surface. The lower part accommodates the LED light source, and includes an arch-shaped lower part refracting surface extended outwards from the lower end of the side surface of the central part. The light radiated from the LED light source is emitted perpendicular to the central axis.