LED Lens with Segmented Curved Sections for Reduced Thickness
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Solution Overview
Problem
Conventional secondary optical lenses for light-emitting diodes in outdoor lighting are thick, leading to inefficiencies in light distribution and increased material usage, which can result in deformation during manufacturing and higher production costs.
Innovation Solution
A secondary optical lens with a reduced thickness design featuring a curved light-projecting surface and a light-incident surface with multiple curved sections and connecting sections, where the distance between connection sides varies, allowing for a more uniform light distribution while minimizing material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional thick secondary optical lens is used, then the light distribution can be controlled, but the material usage increases leading to deformation during manufacturing and higher production costs
Solution Approach 1:
The light-incident surface is divided into multiple curved sections (first, second, third curved sections) with different curvature radii, and connecting sections are introduced between adjacent curved sections. This segmentation allows each region to control light distribution differently while using less material overall, preventing deformation during manufacturing.
Solution Approach 2:
Different regions of the lens have different local properties through varying curvature radii in different curved sections. The first curved section has a different curvature radius than the second and third curved sections, allowing localized optimization of light distribution characteristics while reducing overall material usage.
2Shape
If a thick secondary optical lens is used, then the light distribution pattern can be formed, but the weight increases
Solution Approach 1:
The lens is segmented into multiple functional zones with different curvature characteristics. Each curved section contributes to specific portions of the light distribution pattern, allowing the lens to achieve the desired overall pattern with reduced thickness and weight.
Solution Approach 2:
The curvature radius parameter is varied across different sections of the lens. By changing the curvature radius from the first curved section to the second and third curved sections, the lens achieves diverse light distribution characteristics without increasing overall thickness or weight.
3Shape
If a thick secondary optical lens is used, then the light distribution can be controlled, but the production cost increases
Solution Approach 1:
The complex light distribution control function is segmented across multiple curved sections with different curvature radii. This allows simpler manufacturing of each individual section while achieving the overall complex light distribution pattern, reducing production costs.
Solution Approach 2:
Each curved section is optimized for its specific local function with appropriate curvature radius. This localized optimization simplifies the manufacturing process for each region while maintaining overall light distribution control capability, reducing production costs.
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 lens achieves a uniform light distribution suitable for roadway illumination, reducing manufacturing defects and costs by minimizing material usage and weight, while allowing for increased flexibility in light source arrangement.
Implementation Method 1
The light emitted by the conventional light-emitting diode is refracted upon entering the secondary optical lens, therefore, design parameters such as curvature and thickness of the secondary optical lens may be manipulated for achieving a more uniform light distribution
Data Source
AI summary
A lens, which is adapted to control distribution of light emitted by a light source, includes a curved light-projecting surface distal from the light source, and a light-incident surface opposite to the light-projecting surface. The light-incident surface includes a plurality of curved sections facing the light source, and a plurality of connecting sections. Each of the connecting sections interconnects two adjacent ones of the curved sections, and has opposite first and second connection sides that are respectively connected to the two adjacent ones of the curved sections. A distance between the first connection side and the light source is not equal to a distance between the second connection side and the light source.