Microstructured Light Entry Layer for Low-Reflection Optical Components
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Solution Overview
Problem
Existing transmissive optical components in lighting systems suffer from efficiency losses due to light reflection at flat angles and potential damage from high-performance illuminants, necessitating a solution for high efficiency and longevity.
Innovation Solution
A microstructured functional layer of transparent synthetic resin, such as a clear coat, is applied to the light entry surface, featuring cone-shaped, jagged, or rib-shaped microstructures to reduce reflection and enhance light coupling, while providing heat and UV resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat light entry surface is used, then the structure is simple and manufacturing is easy, but light reflection losses occur at flat angles reducing coupling efficiency
Solution Approach 1:
The patent applies curvature by replacing the flat light entry surface with a microstructured surface featuring cone-shaped, rib-shaped, or grooved microstructures. These curved microfacets redirect light rays that would otherwise reflect at flat angles, guiding them into the optical component body and reducing reflection losses while maintaining manufacturing feasibility through established molding techniques.
Solution Approach 2:
The patent implements local quality by creating microstructures with specific geometric properties (cone-shaped, rib-shaped, grooved) at the light entry surface. Each microstructure is designed with particular dimensions and shapes optimized for its local function of redirecting light, while the overall surface maintains a unified structure that can be manufactured as a single component.
2Illumination intensity
If high-performance illuminants are used, then lighting performance is improved, but heat and UV radiation damage the optical component
Solution Approach 1:
The patent introduces a microstructured functional layer as an intermediary between the high-performance illuminant and the optical component body. This functional layer, composed of transparent synthetic resin, serves as a protective barrier that filters out harmful heat and UV radiation while allowing beneficial light to pass through to the component body, enabling closer proximity to the illuminant without damage.
Solution Approach 2:
The patent employs composite materials by combining the optical component body with a microstructured functional layer made of transparent synthetic resin. This composite structure integrates the optical functionality of the body with the protective properties of the resin layer, which has superior heat and UV resistance, creating a synergistic system that handles both light transmission and environmental protection.
3Productivity
If the light entry surface is exposed to the illuminant, then light coupling is maximized, but overexposure causes efficiency losses due to heat and UV
Solution Approach 1:
The microstructured functional layer acts as an intermediary that enables maximized light coupling while preventing overexposure. The microstructures guide light efficiently into the component body, and the resin layer simultaneously blocks harmful heat and UV radiation, allowing the light entry surface to be positioned closer to the illuminant without suffering efficiency losses from overexposure damage.
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 microstructured layer improves light efficiency by reducing reflection and protects the entry surface from heat and UV damage, allowing closer proximity to illuminants without degradation, thus enhancing the overall performance of the optical component.
Implementation Method 1
the microstructures can cause light to be bundled onto the light entry surface, i.e., the divergence angle of a light beam incident on the functional layer is reduced by appropriate refraction at the microstructures
Implementation Method 2
the synthetic resin of the functional layer has a higher heat resistance, a higher UV resistance and/or a higher hydrolysis resistance than the material of the component body
Implementation Method 3
the synthetic resin of the functional layer has a higher heat resistance, a higher UV resistance and/or a higher hydrolysis resistance than the material of the component body
Data Source
AI summary
A transmissive optical component, in particular a light guide or a lens, for a lighting system, in particular for a motor vehicle lighting device. The component comprises a component body having at least one light entry surface. A microstructured functional layer is arranged on the light entry surface, which has a synthetic resin, in particular a clear coat.