Integrated LED Optic with Tilted Wedge for Light Collimation
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Solution Overview
Problem
Conventional LED lighting systems require a two-stage assembly for optic and LED die integration, which increases complexity and does not efficiently redirect light, limiting light extraction and radiation pattern control.
Innovation Solution
An optic is integrated directly with the LED die, featuring a truncated compound parabolic concentrator and a tilted wedge, allowing for optical contact and substantial light collimation, similar in size to a hemispherical dome overmold, to enhance light extraction and redirection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-stage assembly (separate optic and LED die) is used, then light redirection and extraction can be achieved, but device complexity increases
Solution Approach 1:
The patent merges the optic and LED die into a single integrated unit where the optic is formed directly over the LED die in one manufacturing stage, eliminating the need for separate assembly of optic and die while maintaining light extraction and redirection functions
2Reliability
If a hemispherical dome overmold is used, then light extraction efficiency is improved, but light redirection capability is lost
Solution Approach 1:
The patent applies different optical surface profiles to different regions of the overmold: a hemispherical dome portion for light extraction and a tilted wedge portion with specific angular surfaces for light redirection, allowing each region to perform its specialized function
Solution Approach 2:
The optic combines multiple geometric features (hemispherical dome, tilted wedge, planar surfaces) into a single composite optical structure that performs both extraction and redirection functions simultaneously
3Illumination intensity
If a secondary optic reflector is added to collimate light, then light collimation is achieved, but device complexity and size increase
Solution Approach 1:
The patent combines the collimation function into the primary overmold optic itself by adding tilted wedge surfaces and planar surfaces with specific angles to the hemispherical dome, eliminating the need for a separate secondary reflector optic
4Ease of operation
If multiple separate optical components are used, then light control is improved, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
The patent integrates multiple optical functions (extraction, redirection, collimation) into a single overmolded optic structure that is formed in one manufacturing process directly over the LED die, simplifying both manufacturing and assembly while maintaining full light control capability
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 integrated optic design improves light extraction efficiency and redirects light effectively, reducing the number of LED dies or electrical power required, while maintaining a compact form factor comparable to conventional hemispherical dome overmolds.
Implementation Method 1
The interior conical surface has a vertex located at the axis of symmetry and within the lower exterior surface. The top ends of the interior conical surface and the upper exterior surface join to define an output aperture.
Implementation Method 2
An optic that is in optical contact with an LED die and substantially collimates light from the die.
Data Source
AI summary
A primary optic for a light-emitting diode or device (LED) includes a tilted wedge atop a truncated compound parabolic concentrator (CPC). The CPC includes an input face and a lower exterior surface defined by a tilted parabolic segment rotated about an axis. The bottom end of the lower exterior surface joins the perimeter of the input face. The tilted wedge includes an upper exterior surface above the lower exterior surface, and an interior conical surface surrounded by the lower and the upper exterior surfaces. The upper exterior surface is defined by a tilted straight line rotated about the axis. The interior conical surface is defined by a smooth curve rotated about the axis. The interior conical surface has a vertex located at the axis and within the lower exterior surface. The top ends of the interior conical surface and the upper exterior surface join to define an output aperture.