Multi-material LED Lensing with Nested Silicone Inner Structure
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Solution Overview
Problem
Current LED lighting fixtures face challenges in simplifying manufacturing, reducing component count, and enhancing optical efficiency while maintaining cost-effectiveness and durability, particularly in outdoor settings where secondary lenses play a crucial role in light direction and spread.
Innovation Solution
A multi-material LED lensing arrangement combining a rigid light-transmissive outer structure, such as polymethyl methacrylate or glass, with an optically-clear molded polymeric inner structure like liquid silicone rubber, which is pourable upon molding, allowing for detailed shapes and improved optical efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a multi-material lensing arrangement combining rigid outer structure and pourable polymeric inner structure is used, then manufacturing cycle times are reduced and dimensional replication is improved, but device complexity increases due to multi-material integration
Solution Approach 1:
The patent applies nesting by placing the inner structure (molded from pourable polymeric material) inside the outer structure (rigid light-transmissive material). The inner structure is formed first, then the outer structure is molded around it, creating a nested configuration where one component is embedded within another. This nesting approach allows both materials to be integrated in a single housing while maintaining their individual functional advantages and reducing overall manufacturing steps.
Solution Approach 2:
The patent employs composite materials by combining two distinct materials with different properties: a rigid light-transmissive outer structure material and a pourable polymeric inner structure material. Each material is selected for its specific advantages—the outer structure provides structural integrity and durability, while the inner structure offers optical precision and dimensional stability. This composite approach resolves the contradiction by leveraging the strengths of each material to achieve both reduced manufacturing complexity and improved product performance.
2Use of energy by moving object
If secondary lenses are used to direct light from LED light sources, then optical efficiency and light direction control are improved, but manufacturing complexity and component count increase
Solution Approach 1:
The patent merges the functions of multiple components into a single integrated lensing arrangement. The outer structure and inner structure are combined in one housing, with the inner structure serving as a secondary lens for light redirection. This merging eliminates the need for separate secondary lens components, reducing component count while maintaining optical efficiency. The integrated design allows light from LED sources to be directed effectively through the combined structure without requiring additional discrete optical elements.
3Manufacturing precision
If pourable polymeric material is used for the inner structure, then detailed lens shapes and optical precision are achieved, but material cost and processing complexity increase
Solution Approach 1:
The patent applies parameter changes by utilizing the pourable state of the polymeric material during molding, then transforming it into a solidified state with high dimensional stability. The material's viscosity and flow properties are controlled during the molding process to achieve detailed lens shapes, then the material cures or sets to maintain precise dimensional replication. This parameter transformation allows the material to be easily formed into complex geometries while maintaining manufacturing precision in the final product.
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 solution reduces manufacturing cycle times, increases dimensional replication, enhances optical efficiency, and lowers production costs while maintaining photometric accuracy and durability, addressing the need for energy-efficient and cost-effective LED lighting solutions.
Implementation Method 1
a rigid light-transmissive outer structure (22) which has an outwardly-facing light-exit surface (28) and an outer-structure light-input surface (30); an optically-clear molded polymeric inner structure (24) which has a light-entrance surface (32) and an light-output surface (34)
Data Source
AI summary
An LED lensing arrangement for lighting fixtures includes (1) a rigid light-transmissive outer structure having an outwardly-facing light-exit surface and an outer-structure light-input surface, (2) an optically-clear molded polymeric inner structure having a light-entrance surface and a light-output surface which is adhered to the outer-structure light-input surface, the inner structure being of a material which is pourable upon molding, one example being a liquid silicone rubber (LSR) material, and (3) at least one LED light source secured with respect to and optically coupled to the inner-structure light-entrance surface.