MR16 LED Collimated Light Beam Optical Assembly
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Solution Overview
Problem
Current MR16 LED lamps face challenges with excessive thermal loads due to high-power LED chips, requiring enhanced optical and thermal control to achieve efficient light collimation and extended service life, while traditional lenses are thick and inefficient in heat dissipation.
Innovation Solution
A compact optical assembly with a convex and concave shaped lens configuration, having a height between 2.8 mm and 4 mm, and a 50% thinner structure compared to commercial lenses, utilizing a refractive wall and Bezier shape for improved light collimation and thermal management, reducing thermal resistance and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional MR16 lenses are used for light collimation, then optical performance is achieved, but lens thickness is excessive (6 mm or higher)
Solution Approach 1:
The lens is divided into two separate portions: a first portion with a first optical surface and a second portion with a second optical surface. Each portion has a height of 1-3 mm, together achieving the required optical performance while reducing total thickness compared to traditional single-lens designs (6 mm or higher).
Solution Approach 2:
The patent transitions from a single thick lens to a stacked configuration of two thinner lens portions, utilizing the vertical stacking dimension to achieve the same optical function with reduced overall thickness profile.
2Power
If high-power LED chips are used to increase light output, then lumen output is improved, but thermal load increases excessively
Solution Approach 1:
The patent extracts the thermal management function from the traditional single-lens structure by introducing a heat dissipation layer between the LED chip and the first lens portion. This separate thermal management component enables the use of high-power LED chips while controlling thermal load.
Solution Approach 2:
The optical assembly uses composite material structure combining different materials with complementary properties: the heat dissipation layer material has high thermal conductivity for heat removal, while the lens portions use materials optimized for optical performance, creating a composite system that manages both light and heat effectively.
3Reliability
If traditional single-lens design is used, then manufacturing is simple, but optical and thermal control is insufficient
Solution Approach 1:
The lens system is segmented into two distinct portions with different optical functions, allowing independent optimization of each portion's geometry and material properties for superior optical and thermal control compared to traditional single-lens designs.
Solution Approach 2:
The heat dissipation layer acts as an intermediary component between the LED chip and the optical lens portions, providing thermal management while allowing the optical portions to focus on light collimation and quality control.
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 achieves improved light quality, uniform beam angles, and enhanced thermal performance, with 25% less material usage and 50% reduced thickness, resulting in higher lumen output and extended product life while maintaining similar optical performance to commercial lenses.
Implementation Method 1
an upper portion having a convex shaped lens and a bottom portion having an upper wall configured as an concave shaped lens
Implementation Method 2
MR16 LED lamp with multifaceted reflector (MR) internal reflection (TIR) lens collimates light from the LED
Data Source
AI summary
A lamp for producing a collimated light beam includes at least one light source disposed on a casing, a retaining plate having at least one opening for accommodating an optical assembly. The optical assembly includes an upper portion having a convex shaped lens, a bottom portion having an upper wall configured as a concave shaped lens and having an aperture. The optical assembly further includes an inverted dome shaped shell defined by lateral walls and a refractive wall and a domed portion having the convex shaped lens extending outwardly from the lamp.