Liquid Silicone Diffusion Lens for Uniform Linear Light Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional diffusion lenses for vehicle lamps suffer from optical loss due to air gaps and are not optimized for uniform linear image formation, leading to non-uniform light distribution and increased manufacturing costs.
Innovation Solution
A diffusion lens with symmetrical convex surfaces formed from liquid silicone material, injected directly onto a PCB substrate, eliminating air gaps and allowing for efficient horizontal light diffusion and integration on curved surfaces, reducing the number of LEDs required for uniform linear image implementation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional diffusion lenses with separate fastening portions are used, then the lens can be assembled to the LED, but air gaps are formed causing optical loss
Solution Approach 1:
The diffusion lens is integrated directly with the LED package body as a single component, eliminating the separate fastening portion and air gap. The lens is formed as an extension of the package body itself, creating direct optical contact between the LED chip and the diffusion lens surface.
2Illumination intensity
If conventional diffusion lenses are used, then light can be spread in all directions, but uniform linear image formation is not achieved
Solution Approach 1:
The diffusion lens employs asymmetrical convex surfaces with different curvature radii in different regions. The curvature radius varies from the center to the periphery, and different regions have different curvature characteristics to control light diffusion angles and achieve uniform linear image formation rather than omnidirectional spread.
3Ease of manufacture
If conventional diffusion lenses are used, then manufacturing can proceed with standard processes, but processing and manufacturing costs are increased
Solution Approach 1:
The diffusion lens is manufactured as an integral part of the LED package body through a unified molding process, eliminating the need for separate lens production and assembly steps. This integration reduces the number of manufacturing processes and lowers production costs.
4Illumination intensity
If conventional diffusion lenses with circular band shape are used, then light can be diffused at wide angles, but hot spot portions and dark portions near the optical axis are not alleviated
Solution Approach 1:
The diffusion lens features locally varied surface properties with different curvature radii in different regions. The convex surfaces have gradient curvature characteristics that are optimized for specific zones to control light diffusion patterns and eliminate hot spots and dark portions near the optical axis.
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 significantly reduces optical loss, enhances light diffusion performance, and allows for the use of fewer LEDs, achieving a uniform linear image with improved light uniformity and reduced manufacturing costs.
Implementation Method 1
efficiently diffuse light horizontally
Data Source
AI summary
A diffusion lens may include a plurality of diffusion portions which contacts with an LED, is symmetrical to each other with respect to an optical axis which is a straight direction of the light emitted from the LED, and has convex surfaces.