Lenticular LED Diffuser for Uniform Illumination
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Solution Overview
Problem
LED arrays used for general illumination often produce non-uniform light due to the spacing of high-powered LEDs, resulting in bright spots and reduced light intensity when traditional diffusing elements absorb or misdirect light energy.
Innovation Solution
A lighting assembly with a metal base and a custom-manufactured lenticular diffuser panel that has varying lenticule radii and densities to optimize light diffusion, ensuring uniform illumination without significant light absorption or interference patterns, featuring a central region with a greater diffusion angle and lower lenticule density on the sides to maintain light efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high-powered LEDs are spaced far apart to dissipate heat, then thermal management is improved, but light uniformity deteriorates (creating bright spots)
Solution Approach 1:
The patent applies local quality by varying the lenticule density across different regions of the diffuser panel. The central region has lower lenticule density to allow more light transmission for LEDs that are spaced farther apart, while side regions have higher density to diffuse light from more closely spaced LEDs. This regional variation in diffuser properties compensates for the non-uniform LED spacing and maintains overall light uniformity while allowing improved heat dissipation through increased LED spacing.
2Illumination intensity
If traditional lenticular lenses are used to diffuse light, then light uniformity is improved, but light intensity deteriorates (due to absorption and misdirection)
Solution Approach 1:
The patent applies parameter changes by modifying the optical parameters of the lenticular diffuser, specifically the focal length and curvature of the lenticules. By optimizing these parameters, the diffuser redirects light more efficiently without significant absorption, maintaining higher light intensity while achieving uniform diffusion. This differs from traditional lenticular lenses that have suboptimal parameters resulting in excessive light absorption and energy loss.
3Illumination intensity
If LED density is increased to improve illumination, then light intensity is improved, but thermal management deteriorates (heat dissipation becomes difficult)
Solution Approach 1:
The patent applies local quality by creating regions of different lenticule density in the diffuser panel. Areas with higher LED density have corresponding regions in the diffuser with higher lenticule density to handle the increased light output, while areas with lower LED density have lower lenticule density. This allows the system to optimize illumination in high-density regions without compromising heat dissipation in low-density regions.
Solution Approach 2:
The patent applies segmentation by dividing the diffuser panel into multiple regions with different optical properties. Each region is optimized for its specific LED density and thermal requirements, allowing the overall system to achieve both high illumination output and effective thermal management through localized optimization rather than a uniform design.
4Area of stationary object
If LEDs are placed close together to reduce spacing, then device compactness is improved, but light uniformity deteriorates (creating bright spots)
Solution Approach 1:
The patent applies local quality by varying the lenticule density across different regions of the diffuser panel. Regions with closely spaced LEDs have higher lenticule density to diffuse the concentrated light and reduce bright spots, while regions with more spaced-out LEDs have lower lenticule density to maintain light transmission efficiency. This localized adaptation of diffuser properties maintains light uniformity across the entire array while allowing compact LED placement.
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 provides uniform lighting over a wide area with increased light transmission efficiency, reducing bright spots and mimicking the illumination characteristics of traditional fluorescent bulbs while minimizing light absorption.
Implementation Method 1
Light emitted by the LED array passes through, and is diffused by, the light diffusing material. The light diffusing material has rows of lenticules that run parallel to the linear arrangement of LEDs.
Implementation Method 2
Some attempts have been made to diffuse light produced by linear arrays of LEDs. The use of a diffusing element, such as a lenticular lens diffuses light
Data Source
AI summary
A lighting assembly where the light from multiple LEDs is blended to provide uniform lighting over a wide area without bright spots or interference anomalies. The assembly has a metal base that defines a channel. The channel has a bottom surface and opposing side walls. An array of LEDs is mounted on a circuit board. The circuit board is mounted to the bottom surface of the channel. A panel of light diffusing material is suspended over the LED array between the opposing side walls of the channel. The light diffusing material is configured to have lenticules that run parallel to the alignment of the LEDs. The lenticules vary between regions of the panel. Light emitted by the LED array passes through, and is diffused by, the lenticules. The result is a uniform patch of light that does not have bright areas or dark areas.