Custom Primary Optics for LED Beam Shaping
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Solution Overview
Problem
Standard LED components with standard primary optics often produce undesirable near-field intensity and color variations due to their narrow Lambertian emission profiles, leading to non-uniform luminance distribution in direct emission light fixtures, which can result in aesthetically undesirable hot spots and require additional secondary optics that increase manufacturing complexity and efficiency losses.
Innovation Solution
Custom primary optics are integrated directly onto LED chips or submounts to shape the emission pattern into broader profiles, such as batwing patterns, eliminating the need for secondary optics and reducing efficiency losses, while allowing for more uniform light distribution and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If standard primary optics are used with LED chips, then the LED component structure is simple, but the emission profile is narrow causing non-uniform luminance distribution and hot spots
Solution Approach 1:
The patent applies parameter changes by modifying the primary optic geometry from standard simple shapes to custom-designed profiles with specific curvature radii and surface contours. These geometric parameter changes transform the narrow Lambertian emission profile into broader emission patterns, achieving uniform luminance distribution without adding secondary optics or increasing device complexity.
2Illumination intensity
If secondary optics are added to shape the emission pattern, then the emission profile can be broadened, but the manufacturing complexity and efficiency losses increase
Solution Approach 1:
The patent merges the functions of the primary optic and emission pattern shaping into a single integrated component. By designing the primary optic with custom geometric parameters, it simultaneously performs light collection and beam shaping functions that would otherwise require separate secondary optics, thereby reducing manufacturing complexity and eliminating associated efficiency losses.
Solution Approach 2:
The patent extracts the emission pattern shaping function from the secondary optic and integrates it directly into the primary optic design. This extraction eliminates the need for separate secondary optics while maintaining the desired broad emission profile, reducing both device complexity and manufacturing steps.
3Illumination intensity
If secondary optics are added to shape the emission pattern, then the emission profile can be broadened, but the efficiency losses increase due to additional optical interfaces
Solution Approach 1:
The patent combines the primary optic and emission shaping functions into one component, eliminating the additional optical interfaces that would be created by separate secondary optics. This merging reduces Fresnel losses and absorption at interfaces, thereby improving overall system efficiency while achieving the desired emission profile shaping.
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 custom primary optics provide improved far-field distribution and uniformity in light emission, reducing pixilation and color variations, and enabling a wider range of optical beam profiles without the need for secondary optics, thus enhancing the efficiency and reliability of LED-based lighting systems.
Implementation Method 1
A primary optic is included directly on the LED chip with LED light from the LED chip passing through the primary optic. The primary optic shapes the LED emission pattern into an LED component emission pattern.
Data Source
AI summary
LED components are described having primary optics provide improved LED component emission characteristics. Light fixtures are also described that utilize the LED components to provide improved light fixture emissions. One LED component according to the present invention comprises an LED chip emitting an LED chip emission pattern. A primary optic is included directly on the LED chip with LED light from the LED chip passing through the primary optic. The primary optic shapes the LED emission pattern into an LED component emission pattern with the LED component emission pattern being broader than the LED chip emission pattern.