Optical Distribution Plate for LED Thermal Management
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Solution Overview
Problem
Existing LED light systems face issues with thermal and radiometric power incidents due to the close positioning of light redirection elements, which can lead to undesirable heat and energy management challenges, especially in hazardous environments.
Innovation Solution
The implementation of an optical distribution plate with symmetrically positioned total internal reflection (TIR) and refractive elements that focus and distribute LED light in orthogonal orientations, creating a high angle batwing pattern while increasing the spacing between the optic surface and the LED, thereby reducing thermal and radiometric power incidents and enhancing airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light redirection elements are positioned close to the LED, then the desired beam distribution pattern is achieved, but thermal and radiometric power incident on the optic plate increases
Solution Approach 1:
The patent transitions from a single-surface light redirection approach to a dual-surface optical distribution plate. The first surface (facing the LED) and second surface (opposite surface) work together to redirect light, with the second surface positioned at a greater distance from the LED. This dimensional expansion allows the system to maintain effective beam distribution while reducing thermal and radiometric power incident on the optic plate structure.
Solution Approach 2:
The optical distribution plate serves as an intermediary component between the LED and the final beam distribution. By incorporating both a first surface for focusing and a second surface for distribution, the plate mediates the light path to achieve the desired beam pattern while reducing direct thermal and radiometric exposure to the optic plate structure.
2Object-affected harmful factors
If the optical distribution plate is positioned farther from the LED, then thermal and radiometric power incidents are reduced, but the beam distribution pattern may be compromised
Solution Approach 1:
The optical distribution plate is segmented into two distinct surfaces with different functions: the first surface (adjacent to the LED) is optimized for focusing light, while the second surface (opposite surface) is optimized for distributing light in the desired beam pattern. This segmentation allows each surface to be independently optimized for its specific function, maintaining beam quality while enabling greater spacing from the LED to reduce thermal and radiometric power incidents.
Solution Approach 2:
Different regions of the optical distribution plate are given different optical properties and geometries. The first surface incorporates features for focusing light from the LED, while the second surface incorporates features for distributing light in specific beam patterns (such as IESNA Type I or Type III). This local differentiation of optical quality allows the plate to maintain effective beam distribution even when positioned farther from the LED.
3Illumination intensity
If individual bubble domes are used to redirect light, then the required distribution pattern is achieved, but the device complexity increases due to multiple components
Solution Approach 1:
The patent merges the functions of multiple separate light redirection components into a single integrated optical distribution plate. The plate combines focusing elements, light redirection elements, and distribution elements that would traditionally require separate bubble domes and redirectors into one unified component. This integration maintains the desired light distribution pattern while significantly reducing device complexity and the number of separate parts.
Solution Approach 2:
The optical distribution plate is designed as a multi-functional component that simultaneously performs focusing, light redirection, and beam distribution functions. By incorporating both a first surface for focusing and a second surface for distribution, the single plate replaces what would traditionally require multiple specialized components, achieving universal functionality within one element.
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 effectively reduces thermal and radiometric power incidents on the optic surface, improving the performance and energy efficiency of LED light systems while maintaining desired beam patterns, such as IESNA Type I and Type III patterns, without requiring significant modifications to existing housings.
Implementation Method 1
a first surface that focuses LED light from the corresponding LED in a first orientation
Implementation Method 2
a first surface that focuses LED light from the corresponding LED in a first orientation
Implementation Method 3
a set of single total internal reflection, in short TIR, elements positioned symmetrically adjacent the centerline plane wherein each single TIR element reflects LED light substantially away from the centerline plane
Implementation Method 4
a set of refractive elements positioned symmetrically about the centerline plane and outside of the set of single TIR elements, wherein each refractive element of the set of refractive elements refracts LED light substantially away from the centerline plane
Implementation Method 5
a set of double TIR elements positioned symmetrically about the centerline plane and outside of the set of refractive elements, wherein each double TIR element reflects LED light both away from and across the centerline plane
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A light system includes a substrate, one or more light emitting diodes (LEDs) coupled to the substrate, and an optical distribution plate positioned proximate the substrate. The optical distribution plate includes one or more optical structures each corresponding to the one or more LEDs. The one or more optical structures include a first surface that focuses LED light from the corresponding LED in a first orientation, and an opposite second surface that distributes LED light from the LED in a second orientation. The second orientation being substantially orthogonal to the first orientation.