LED Optical System with Multi-Level Secondary Optics for Uniform Illumination
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Solution Overview
Problem
Lighting systems using LEDs struggle to achieve uniform and efficient light distribution, as they require multiple LEDs and secondary optics to mimic the light output of traditional lamp sources, leading to inefficiencies and waste due to the inability to replicate the radial illumination pattern of standard light sources.
Innovation Solution
A lighting system with a 2-D array of LEDs, utilizing a combination of primary and secondary optics with different categories (high, medium, low) to control light distribution, allowing precise alignment and combination of illumination patterns for uniform coverage and reduced waste, using prismatic portions and teeth to refract and reflect light effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large array of LEDs is used to produce equivalent light output to high wattage standard lamps, then light output is improved, but device complexity increases
Solution Approach 1:
The patent divides the lighting system into multiple discrete LED modules, each with its own primary and secondary optics. This segmentation allows the system to achieve high total light output through aggregation of multiple controlled sources while maintaining manageable complexity through modular design and standardized optical components for each module.
Solution Approach 2:
The patent transitions from traditional single-point light sources to a two-dimensional array of LED modules with controlled spatial distribution. By arranging LEDs in a grid pattern and applying secondary optics at multiple levels, the system achieves uniform illumination across large areas without requiring excessive individual components, thus managing complexity while delivering high light output.
2Ease of manufacture
If standard optical systems are used with LED arrays, then ease of manufacture is improved, but illumination uniformity deteriorates
Solution Approach 1:
The optical control system is segmented into primary optics attached to individual LEDs and secondary optics positioned at strategic locations. This segmentation allows each optical element to be manufactured and optimized independently using standard techniques, while the combined system achieves superior illumination uniformity that would be impossible with a single monolithic optical design.
Solution Approach 2:
Different regions of the illumination system employ different optical configurations tailored to local requirements. Secondary optics are selectively positioned to address specific uniformity challenges in different areas of the illumination pattern, allowing each zone to be optimized independently while maintaining overall system manufacturability through modular assembly.
3Ease of operation
If individual secondary optics are used for each LED, then light distribution control is improved, but device complexity increases
Solution Approach 1:
The patent implements a hierarchical optical control structure where primary optics are attached to individual LEDs for localized light shaping, and secondary optics are positioned at intermediate levels to provide broader distribution control. This segmentation enables precise light distribution management at multiple scales while avoiding the complexity of a fully integrated single-level optical system.
Solution Approach 2:
The patent introduces multiple levels of optical control in the vertical dimension, with primary optics at the LED level and secondary optics at elevated positions. This multi-level arrangement provides sophisticated light distribution control by addressing both localized and area-wide illumination requirements simultaneously, achieving superior control without requiring excessive individual components.
4Reliability
If LEDs are spaced apart for heat dissipation, then reliability is improved, but illumination coverage deteriorates
Solution Approach 1:
The patent compensates for the reduced light output from spaced-apart LEDs by introducing secondary optics positioned at elevated vertical levels. This multi-level optical arrangement extends the effective illumination coverage area by redirecting light from higher positions to fill gaps between spaced LEDs, thus maintaining reliable thermal spacing while achieving comprehensive area coverage.
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 system achieves a high degree of uniformity and efficiency in light distribution, minimizing waste and exceeding the light output of standard lamp sources by directing light more effectively over larger areas, with the ability to create unique illumination patterns tailored for specific applications.
Implementation Method 1
a primary optic for collecting and collimating light from the LED
Implementation Method 2
prismatic portion(s) or 'teeth' that refract and reflect light rays in a predetermined manner
Implementation Method 3
prismatic portion(s) or 'teeth' that refract and reflect light rays in a predetermined manner
Data Source
AI summary
An optical system for lighting fixtures uses light emitting diodes arranged in a 2-D array. In one embodiment, a lighting system comprises a framework carrying a plurality of diodes, where each diode has an associated optic that projects the light with a “high,”“medium” or “low” vertical throw, as provided by prismatic “teeth” that refract and reflect light rays in a predetermined manner so that the combined illumination patterns of each diode can blend to generally uniformly illuminate a target surface without dark spots or regions. Each optic has a common primary portion and a selected secondary portion whose tooth/teeth have a “swept” geometry for better angular (vertical and/or horizontal) control of light rays. Structural variations between different secondary portions reside in various factors, including plurality of teeth, length of the tooth along the longitudinal axis A, curvature(s) in the vertical and/or horizontal directions, and angularity or tightness of curvature of the swept geometry.