Modified Blob Optic for Asymmetric LED Beam Control
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Solution Overview
Problem
Existing LED lighting systems are inefficient in directing light downwards, resulting in energy loss and increased greenhouse gas emissions due to the need for canted fixtures that send light upwards into the sky, and current solutions like reflectors and lenses suffer from surface losses and inability to create radially asymmetric beams effectively.
Innovation Solution
A lighting system utilizing a modified blob optic with a radially symmetric design that refracts light from an LED package to redirect peripheral light rays downwards, allowing for customizable beam profiles by modifying the inner surface of the optic to achieve user-defined illumination patterns, such as Type I-V street light patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If canted fixtures or curved armatures are used to create spread beams, then broad beam illumination is achieved, but a substantial amount of light is directed upward into the sky causing energy loss
Solution Approach 1:
The patent applies asymmetry by modifying the symmetric dome lens into an asymmetric optic with an undercut surface. This undercut creates a reflective surface that redirects light rays that would otherwise escape upward, bending them downward to illuminate the street. The asymmetric geometry allows selective redirection of light paths without requiring canted fixtures, thereby maintaining broad beam illumination while eliminating skyward light waste.
Solution Approach 2:
The patent introduces a new dimensional element by adding an undercut surface dimension to the traditional dome lens. This additional geometric dimension creates a secondary reflective surface that interacts with light rays in a third spatial dimension, redirecting them downward. This dimensional modification enables the optic to control light distribution in both horizontal and vertical planes simultaneously, achieving broad illumination without upward light loss.
2Illumination intensity
If reflectors and lenses are used to collect and spread LED energy, then broad beam is achieved, but surface losses occur due to metalizing techniques and lack of anti-reflective coatings
Solution Approach 1:
The patent merges the refractive function of the dome lens with the reflective function of the undercut surface into a single integrated optic. Instead of using separate reflectors and lenses that each incur surface losses, the invention combines both optical functions in one component. The dome portion refracts light while the undercut portion reflects light, and both functions are optimized within the same molded structure, eliminating the cumulative surface losses of multiple separate components.
Solution Approach 2:
The patent employs composite optical design by integrating materials or surface treatments that simultaneously provide refraction and reflection properties. The optic may use different refractive indices in different zones or apply selective coatings that enhance both refractive and reflective functions. This composite approach allows the single optic to achieve the combined effect of multiple components with reduced total surface loss.
3Reliability
If conventional dome lenses or packaging are used, then LED protection is provided, but no undercut surface exists to redirect peripheral light rays
Solution Approach 1:
The patent segments the dome lens function into two distinct zones: the upper dome portion for protection and initial refraction, and the lower undercut portion for reflecting peripheral light rays. This segmentation allows each zone to be optimized for its specific function while working together as a unified optic. The dome continues to protect the LED, while the added undercut segment captures and redirects previously lost peripheral rays.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the undercut surface geometry during optic manufacturing to intercept and redirect light rays before they escape into the sky. The undercut is designed with specific angles and curvatures that predictably bend light paths downward, ensuring that peripheral rays are captured and redirected in advance rather than allowing them to be lost.
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 solution significantly reduces energy loss by redirecting peripheral light rays, achieving a more efficient and cost-effective LED lighting system that can produce radially asymmetric beams with improved consistency and reduced energy wastage, enhancing the cost-benefit comparison with traditional lighting methods.
Implementation Method 1
A lighting system utilizing a modified blob optic with a radially symmetric design that refracts light from an LED package to redirect peripheral light rays downwards
Data Source
Figure 1
AI summary
A predetermined illuminated surface pattern is generated from a predetermined energy distribution pattern of an LED light source within an LED package having a light transmitting dome. An estimated optical transfer function of a lens shape of an optic is defined by the shape of an exterior and inner surface which envelopes at least in part the light transmitting dome of the LED package. An energy distribution pattern is obtained by combination of the estimated optical transfer function and the predetermined energy distribution pattern of the light source. A projection of the energy distribution pattern onto the illuminated surface is determined. The projection is compared to the predetermined illuminated surface pattern. The estimated optical transfer function is then modified and the steps repeated until acceptable consistency is achieved between the projection and the predetermined illuminated surface pattern.