LED Lens with Segmented Inner Cavity for Light Direction Control
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Solution Overview
Problem
Existing LED optics fail to efficiently control the direction of light emission, resulting in loss of light and inefficient illumination patterns due to undesirable light rays being blocked, which decreases the overall efficiency of LED illuminators.
Innovation Solution
A lens design with an inner cavity surface featuring distinct regions for refracting light rays, including an axis-adjacent, second, and middle inner regions, and corresponding outer surface regions, which progressively refract light away from the axis, combined with a peripheral inner surface for total internal reflection, to maximize light output and control its direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If prior lenses block or prevent undesirable light rays from exiting, then desired illumination pattern is achieved, but light loss increases and efficiency decreases
Solution Approach 1:
The lens surface is divided into multiple zones (first zone, second zone, third zone) with different refraction characteristics. Each zone selectively redirects light rays from specific angular ranges, allowing desirable light to be directed toward the target area while undesirable light is redirected to different locations, eliminating the need for blocking and reducing light loss.
Solution Approach 2:
Different regions of the lens are assigned different optical functions: the first zone handles light rays within a first angular range, the second zone handles light rays within a second angular range, and the third zone handles light rays within a third angular range. This local differentiation allows precise control over light distribution without blocking any rays.
2Area of stationary object
If LEDs emit light at wide range of angles, then light coverage is increased, but control of refraction direction becomes difficult
Solution Approach 1:
The lens is segmented into multiple zones that each handle specific angular ranges of incoming light. The first zone processes light rays at smaller angles, the second zone processes light rays at intermediate angles, and the third zone processes light rays at larger angles. This segmentation transforms the complex problem of controlling wide-angle light into manageable zones with predictable refraction behavior.
Solution Approach 2:
The solution adds angular dimension control by creating zones that correspond to different angular ranges. Each zone is designed to refract light rays based on their angle of incidence, effectively adding angular selectivity as a new dimension of control to the optical system.
3Ease of operation
If only portion of light is refracted in desired direction, then refraction control is achieved, but remaining light exits with little control causing inefficiency
Solution Approach 1:
The lens is designed as a universal optical element that handles all incoming light rays regardless of their angle of incidence. Every ray that enters the lens is processed by an appropriate zone and redirected in a controlled manner, eliminating uncontrolled light loss while maintaining refraction control.
Solution Approach 2:
The lens provides continuous control over all light rays across the entire angular spectrum. Rather than controlling only a portion of light, the multi-zone design ensures that every ray within the lens's field of view is actively managed and redirected toward useful illumination areas, maintaining continuous useful action across all wavelengths and angles.
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 design significantly improves light output efficiency by directing almost all emitted light in a desired manner, reducing light loss and enhancing illumination uniformity, thus overcoming the limitations of prior art.
Implementation Method 1
The inner-cavity surface includes an axis-adjacent first inner region, a second inner region spaced from the first inner region, and a middle inner region which joins the first and second regions. The axis-adjacent first inner region is configured for refracting emitter light rays away from the axis. The second inner region is configured for refracting emitter light rays toward the axis.
Implementation Method 2
A peripheral inner surface is provided which is configured for total internal reflection of light from a light emitter.
Data Source
AI summary
A lens for distribution of light from a light emitter having an emitter axis. The lens including an outer surface receiving light from the inner surface which defines an inner cavity and includes an axial inner-surface portion of a conical shape formed by a substantially cross-sectionally linear inner region extending outwardly from positions at the emitter axis toward an open end of the inner cavity. An LED light fixture comprising a mounting structure supporting a plurality of spaced LED light sources with a plurality of the lenses each in alignment with a corresponding one of the light sources.