LED Optical Assembly with Dual Focal Point Reflector and Removable Lenses

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Solution Overview

Problem

Current LED optical assemblies face challenges in efficiently directing light output from LEDs with varying light distribution characteristics and manufacturing tolerances, often resulting in suboptimal light distribution patterns and heat management.

Innovation Solution

The LED optical assembly incorporates a dual focal point reflector and removably coupled optical lenses with prismatic areas, allowing for adjustable light direction and distribution. The reflector bank features individual reflectors with distinct focal points to accommodate different LED configurations, while optical lenses can be exchanged for specific light distribution characteristics, and heat management is enhanced with a heatsink.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single fixed reflector design is used, then manufacturing is simplified, but it cannot accommodate LEDs with varying light distribution characteristics and manufacturing tolerances

Engineering Contradiction:

Improveaccommodation of varying LED light distribution characteristicsVSAvoidreflector design complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The reflector bank is divided into multiple individual reflectors, each with its own focal point optimized for specific LED types. This segmentation allows each reflector to be tailored for particular light distribution characteristics while maintaining overall system simplicity through modular architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflector bank serves multiple functions by incorporating reflectors designed for different LED configurations within a single assembly. This multi-functionality allows the same reflector bank structure to accommodate various LED types and light distribution patterns without requiring separate reflector designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If optical lenses are permanently fixed, then assembly is simplified, but adjustment and replacement for different light distribution characteristics becomes difficult

Engineering Contradiction:

Improveadjustability of light direction and distributionVSAvoidlens coupling mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The optical lenses are designed with removable and reconfigurable coupling to the reflectors, allowing them to be adjusted, removed, or replaced. This dynamic coupling mechanism enables adaptation to different light distribution requirements while maintaining a relatively simple overall assembly structure.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If light distribution is optimized for specific LED configurations, then illumination precision is improved, but the system cannot accommodate manufacturing tolerances and LED variations

Engineering Contradiction:

Improvelight distribution precisionVSAvoidtolerance to LED configuration variations

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

Each individual reflector is designed with specific local optical qualities and focal points optimized for particular LED types. This local quality optimization allows precise light distribution for each LED configuration while the overall bank provides versatility through its diverse reflector collection.

Inventive Principle:

Principle #3Local quality

4Temperature

If a fixed optical configuration is used, then heat management is compromised, but adjustable configurations increase structural complexity

Engineering Contradiction:

Improveheat management effectivenessVSAvoidadjustable configuration structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The modular reflector and lens configuration allows for segmented heat management, where each reflector-lens-LED assembly can be independently optimized for thermal performance. The segmentation enables targeted heat management approaches without requiring complex integrated thermal management structures.

Inventive Principle:

Principle #1Segmentation

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 enables precise control over light distribution, improving the directional efficiency of LED light output and accommodating various LED configurations, while also effectively managing heat, resulting in enhanced illumination patterns and performance.

Implementation Method 1

an optical lens with prismatic areas for directing light in different directions

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

a reflector bank with individual reflectors, each having a focal point

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

heat management is enhanced with a heatsink

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8157414B2LED optical assembly

Publication Date: 2012.04.17 SIGNIFY HOLDING BV

AI summary

An LED optical assembly is provided having a support surface having a plurality of light emitting diodes, a plurality of reflectors, and a plurality of optical lenses. Each reflector is positioned over a corresponding light emitting diode and at least one optical lens is placed over a corresponding reflector.