Lens Assembly Gap Structure for Uniform LED Color Temperature

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Solution Overview

Problem

Phosphor converted LEDs, such as white phosphor converted LEDs, typically exhibit angular correlated color temperature (CCT) deviation, resulting in a non-uniform color temperature across different emission angles, which affects the appearance of light patterns.

Innovation Solution

A lighting device is designed with a lens assembly and an elastomer encapsulation system that includes a gap between the lens and the elastomer, allowing for light mixing and collimation to achieve a uniform color temperature. The lens assembly comprises a lens with a reflective surface and a scattering element, and the elastomer is separate from the lens to facilitate light redirection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If phosphor converted LEDs are used to create white light, then the lighting device can achieve broad spectrum illumination, but angular correlated color temperature deviation occurs resulting in non-uniform color temperature across different emission angles

Engineering Contradiction:
Improvebroad spectrum illuminationVSAvoidcolor temperature uniformity
Core Design Contradiction:
Illumination intensityVSStability of the object's composition

Solution Approach 1:

The lighting device is segmented into distinct functional components: the LED light source, the lens assembly with separate optical elements, and the elastomer encapsulation. This segmentation allows each component to be optimized independently - the lens assembly handles light redirection while the elastomer provides color mixing, resolving the contradiction between broad spectrum illumination and color temperature uniformity

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The elastomer acts as an intermediary medium between the LED light source and the external environment. It receives light with angular CCT deviation and transforms it through scattering and mixing processes, converting the non-uniform light into uniformly mixed light that maintains broad spectrum characteristics while achieving color temperature uniformity

Inventive Principle:
Principle #24Intermediary (Mediator)

2Device complexity

If the elastomer is placed in direct contact with the lens, then the structure is simplified, but light mixing and collimation effectiveness is reduced due to refractive index matching

Engineering Contradiction:
Improvestructural simplicityVSAvoidlight distribution uniformity
Core Design Contradiction:
Device complexityVSStability of the object's composition

Solution Approach 1:

The elastomer is extracted from direct contact with the lens by introducing a gap between them. This separation removes the constraint of refractive index matching that would occur with direct contact, allowing the elastomer to perform its light mixing function more effectively while the lens maintains its light redirection function

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The gap between the lens and elastomer creates an optical feedback path where light can be redirected by the lens, then scattered and mixed by the elastomer, and potentially reflected back into the lens. This feedback loop enhances the light mixing process and improves color temperature uniformity without requiring the elastomer to be in direct contact with the lens

Inventive Principle:
Principle #23Feedback

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 solution effectively reduces angular CCT deviation, ensuring a uniform color temperature across a range of emission angles, improving the light's appearance and consistency.

Implementation Method 1

the reflector having a reflective surface that faces the lateral surface of the lens and is disposed between the elastomer and the lateral surface of the lens... the reflective surface is configured to reflect at least some light from the lateral surface of the lens back into the lens

Methodology Applied
Scientific EffectReflection: Reflection

Implementation Method 2

The lens assembly comprises a lens with a reflective surface and a scattering element

Methodology Applied
Scientific EffectScattering: Scattering

Data Source

PatentUS11867382B2Lighting system with lens assembly
Publication Date: 2024.01.09 KORRUS INC
  • US11867382B2 patent drawing
  • US11867382B2 patent drawing
  • US11867382B2 patent drawing

AI summary

According to at least one aspect, a lighting device is provided. The lighting device comprises a circuit board, a light emitting diode (LED) mounted to the circuit board and configured to emit light, a lens disposed over the LED having a bottom surface facing the circuit board, a top surface opposite the bottom surface, and a lateral surface between the top and bottom surfaces, and an elastomer encapsulating at least part of the circuit board. The elastomer may not be in contact with at least part of the lateral surface of the lens so as to form a gap between the elastomer and the lateral surface of the lens.