LED Lamp Optical Lens Protrusion Design for Uniform Light Distribution
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Solution Overview
Problem
LED lamps with existing optical lenses suffer from uneven local light distribution, resulting in a dark band in the middle of the light pattern, which affects the uniformity of light emission.
Innovation Solution
An optical lens design featuring a dome structure with a protrusion that includes oppositely disposed first and second side surfaces, where the second optical surface is connected directly to the external surface of the dome, forming a transition surface that improves light distribution evenness, with the boundary line of these surfaces positioned above the external surface, and an intersection angle between the second optical surface and a vertical surface ranging from 0 to 60 degrees.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the boundary line of the second optical surface and the first optical surface is disposed at the external surface of the dome structure, then the manufacturing is simpler, but the local uniformity of light distribution becomes poor resulting in a dark band in the middle of the light pattern
Solution Approach 1:
The patent applies local quality by making different parts of the optical lens have different functions. Specifically, the second optical surface is designed with a specific inclination angle (0-60 degrees) relative to the vertical direction, creating a localized optical function that redirects light. This localized modification at the boundary region between the first and second optical surfaces ensures uniform light distribution in the previously dark central region without requiring complex overall redesign
Solution Approach 2:
The patent applies parameter changes by modifying the inclination angle parameter of the second optical surface. By setting the inclination angle between 0 and 60 degrees relative to the vertical direction, the optical path of light is changed, which redirects light to fill the dark band region. This parameter adjustment transforms the optical performance from non-uniform to uniform distribution
2Illumination intensity
If the second optical surface is connected directly with the external surface, then the light distribution evenness is improved, but the device complexity increases due to the additional optical surface configuration
Solution Approach 1:
The patent applies merging by integrating the second optical surface directly with the external surface of the dome structure. The second optical surface is formed as a continuous, smooth transition from the external surface, eliminating the need for separate components or complex assembly. This merging approach maintains structural simplicity while achieving improved light distribution evenness through the optimized optical path
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 new optical lens design significantly reduces the visibility of the dark band in the light pattern, enhancing local light distribution evenness and increasing luminous flux, resulting in a more uniform light emission pattern.
Implementation Method 1
The dome structure has an external surface, the protrusion structure is disposed protruding from the external surface of the dome structure with oppositely-disposed first side surface and second side surface. The first side surface includes a first optical surface and a second optical surface... the second optical surface is connected directly with the external surface and further connected between the external surface of the dome structure and the first optical surface
Data Source
AI summary
A LED lamp and an optical lens thereof are provided. The LED lamp includes a LED light source and an optical lens covering the LED light source. The optical lens includes a dome structure and a protrusion structure. The dome structure has an external surface. The protrusion structure is disposed protruding from the external surface and includes oppositely-disposed first and second side surfaces. The first side surface includes first and second optical surfaces. The second side surface includes a third optical surface. The second optical surface is connected immediately to the external surface and further connected between the external surface and the first optical surface. A boundary line of the second and the first optical surfaces is not disposed at the external surface. The third optical surface and the external surface are immediately connected. Accordingly, local uniformity of light distribution of the optical lens is improved.