LED Luminaire Lens Array with Offset Sublenslets
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Solution Overview
Problem
Existing LED light sources using non-imaging optics or lens arrays face challenges in achieving uniform illumination due to the inefficiency and high cost of total internal reflection-based compound parabolic collectors and the limitations of aspheric Fresnel lenses in capturing and redirecting light to desired areas.
Innovation Solution
A light source comprising an LED array with a lens array of lenslets, where each lenslet is divided into sublenslets with optical centers offset from the geometric center, allowing for more efficient light distribution and increased illumination by utilizing the dark areas of the lenslets to illuminate far corners and other needed areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If non-imaging optics (CPCs) are used over each LED, then light capture efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides each lenslet into multiple sublenslets with different optical centers, creating a segmented optical structure that captures light from different angles more effectively than a single centralized lens, thereby improving light capture efficiency while maintaining simpler manufacturing
Solution Approach 2:
The patent uses molded lens arrays where multiple identical lenslets are created through molding processes, allowing for mass production and reducing manufacturing complexity and cost while maintaining consistent optical performance across the array
2Ease of manufacture
If non-imaging optics (CPCs) are molded into the array, then manufacturing complexity is reduced, but illumination uniformity deteriorates
Solution Approach 1:
By segmenting each lenslet into multiple sublenslets with different optical centers, the patent creates directional light redistribution that compensates for the simplified molded structure, achieving uniform illumination across the illuminated area while maintaining manufacturing simplicity
Solution Approach 2:
Different sublenslets within each lenslet have different optical centers positioned to redirect light to specific regions, creating local variations in light distribution that collectively achieve uniform overall illumination, thus improving illumination uniformity while keeping the molded structure simple
3Ease of operation
If lens optical centers are centered on LEDs, then alignment is simplified, but illumination uniformity deteriorates
Solution Approach 1:
The patent segments each lenslet into sublenslets whose collective optical centers are offset from the LED position, allowing the lens array to maintain simple alignment with the LED array while the segmented structure redistributes light to achieve uniform illumination across the illuminated area
Solution Approach 2:
The patent introduces asymmetric positioning of optical centers relative to the LED and lenslet geometry, creating intentional light redistribution patterns that achieve uniform illumination while the overall lens array maintains simple symmetric alignment with the LED array
4Manufacturing precision
If lenslets are positioned with optical centers on LEDs, then light direction control is improved, but light distribution uniformity deteriorates
Solution Approach 1:
The patent segments each lenslet into multiple sublenslets with different optical centers that collectively control light direction more precisely than a single optical center, achieving both precise light direction control and uniform distribution across the illuminated area
Solution Approach 2:
Different sublenslets are designed with different optical centers to redirect light to different regions of the illuminated area, creating local light direction control that collectively achieves uniform overall distribution, thus resolving the contradiction between direction control precision and distribution uniformity
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 configuration enhances light distribution, increasing illumination levels by a factor of two to four and allows for more efficient use of the lenslet area, providing a cost-effective and uniform illumination pattern across a wider angle.
Implementation Method 1
a lens array containing a plurality of lenslets. The lens array is aligned with the LED array such that one lenslet is disposed over each LED
Implementation Method 2
each of said plurality of lenslets comprises at least first and second sublenslets having first and second respective optical centers, and wherein at least one of said first and second optical centers deviates from the geometric center of the lenslet
Data Source
AI summary
A light source is provided which comprises an LED array containing a plurality of LEDs, and a lens array containing a plurality of lenslets. The lens array is aligned with the LED array such that one lenslet is disposed over each LED, wherein each of said plurality of lenslets comprises at least first and second sublenslets having first and second respective optical centers, and wherein at least one of said first and second optical centers deviates from the geometric center of the lenslet.