LED Lighting Assembly with Merged Collimator Lens for High Irradiance
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Solution Overview
Problem
Traditional LED UV curing systems have low output power, making it difficult to replace mercury vapor lamps in high-intensity applications, and pose a risk of contact with the curing substrate due to the need for close proximity.
Innovation Solution
A high irradiance LED system with a long working distance is achieved by arranging multiple LEDs in rows separated by an intermediate area, with an integral optical element featuring collimator lens portions that merge to focus light in a parallel line above the LEDs, allowing for secure distance from the curing material and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED arrays are used at very close range to achieve high irradiance, then the curing intensity is sufficient, but the curing system risks coming into contact with the substrate being cured
Solution Approach 1:
The patent transitions from point-source LED illumination to a line-focus illumination system by arranging multiple LEDs in rows with corresponding collimator lens portions that merge to create a focused line rather than a point focus. This dimensional change allows the light to be concentrated along a line extending parallel to the LED rows, enabling the curing system to maintain high irradiance at a longer working distance without contacting the substrate.
Solution Approach 2:
The patent merges multiple collimator lens portions from different LED rows into a single integrated optical element. The collimator lens portions of different rows are merged together above the intermediate area to form one single optical element, which focuses light from multiple LEDs into a unified focus line, thereby achieving high irradiance distribution along the entire line while maintaining a safe working distance.
2Use of energy by moving object
If traditional mercury vapor lamps are replaced with LED based UV curing systems, then energy consumption is reduced, but output power becomes insufficient for high intensity applications
Solution Approach 1:
The patent divides the illumination system into multiple segments - specifically, multiple LEDs arranged in rows with corresponding collimator lens portions for each row. By segmenting the light source into multiple individual LEDs rather than using a single high-power source, the system achieves cumulative high output power while maintaining LED energy efficiency. Each LED segment contributes to the overall irradiance, and the segmented approach allows for better thermal management and energy efficiency compared to a single mercury vapor lamp.
Solution Approach 2:
The patent combines multiple LED light sources and their corresponding collimator lens portions into a unified system where the collimator lens portions merge to form a single optical element. This merging of multiple low-power LED segments creates a high-power equivalent system that can replace mercury vapor lamps in high-intensity applications while retaining the energy efficiency advantages of LEDs.
3Length of moving object
If multiple LEDs are arranged in rows with merged collimator lens portions, then a focus line is created at a distance, but the optical element complexity increases
Solution Approach 1:
The patent merges multiple individual collimator lens portions into a single integrated optical element. Instead of having separate optical components for each LED row, the collimator lens portions are merged together above the intermediate area to form one single optical element that handles illumination from multiple LED rows simultaneously. This merging approach creates the complex focus line functionality while consolidating the optical structure into a single manufacturable component.
Solution Approach 2:
The single optical element serves multiple functions: it acts as a collimator for multiple LED rows, focuses light from different rows into a unified focus line, and provides structural support for the entire LED array. This multi-functional design achieves the long working distance and focus line creation while avoiding the need for multiple separate optical components, thereby managing complexity through functional integration.
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 solution provides a high irradiance LED system with a long working distance, enabling secure curing of materials without risk of contact and maintaining efficiency across the LED array, suitable for high-power applications like continuous curing processes.
Implementation Method 1
one integral optical element on top of the multiple LEDs in order to shape light emitted from each of the multiple LEDs, where the optical element comprises one collimator lens portion per row of LEDs extending along the row of LEDs... focus the light emitted from the rows of LEDs in a focus line extending parallel to the rows of LEDs at a focus distance above the optical element
Implementation Method 2
the collimator lens portions seen in a direction perpendicular to the row of LEDs are shaped in order to provide an off-axis focus for each of the collimator lens portions, where the shapes are adapted to each other in order to focus the light emitted from the rows of LEDs in a focus line
Data Source
AI summary
A lighting module and a lighting assembly provide high irradiance at long working distances. The lighting module includes at least two rows of multiple LEDs separated from each other by an intermediate area between the rows and one integral optical element on top of the at least two rows of multiple LEDs. The one integral optical element includes one collimator lens portion per row of LEDs extending along the row of LEDs. The collimator lens portions of different rows are merged together above the intermediate area. The collimator lens portions, seen in a direction perpendicular to the at least two rows, provide an off-axis focus for the one collimator lens portion, and focus light emitted from the at least two rows of multiple LEDs in a focus line extending parallel to the rows of LEDs at a focus distance above the optical element.