Non-Circular Optic with Cavity for Uniform LED Illumination
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Solution Overview
Problem
Current illumination systems using light emitting diodes (LEDs) face challenges in achieving uniform light distribution, particularly when a circular optic is used with non-circular apertures, resulting in irregularly lit areas and dark regions.
Innovation Solution
A non-circular optic, such as a square optic, with a base region, rim, and projection that includes total internally reflective surfaces and a convex or concave cavity to receive and distribute light, ensuring even illumination by reflecting light towards the exit surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular optic is used with a non-circular aperture, then the optic structure is simple and easy to manufacture, but the light distribution becomes non-uniform with dark regions in corners
Solution Approach 1:
The patent applies asymmetry by changing the optic shape from circular to non-circular (square, rectangular, or polygonal) to match the aperture geometry. This asymmetric design eliminates the mismatch between optic and aperture shapes, preventing dark regions in corners and achieving uniform light distribution across the entire aperture surface.
Solution Approach 2:
The patent implements local quality by adding specific geometric features to the optic structure, including angled surfaces (45-degree angles), cavity structures, and prismatic elements at specific locations. These localized structural modifications redirect light rays to ensure even illumination distribution across different regions of the aperture, particularly addressing corner areas that would otherwise be dark.
2Illumination intensity
If a non-circular optic with complex geometry is used, then uniform light distribution is achieved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the optic into distinct functional zones: a base region, a projection extending from the base, and a cavity within the projection. Each segment serves a specific optical function - the base provides structural support, the projection creates the non-circular aperture shape, and the cavity redirects light rays. This segmented approach achieves uniform illumination while maintaining manufacturability through modular geometry.
Solution Approach 2:
The patent utilizes curved surfaces, specifically a convex cavity bottom surface, to redirect and distribute light rays uniformly across the aperture. The convex curvature of the cavity bottom surface helps to scatter and redistribute light rays that would otherwise create hot spots or dark regions, achieving uniform illumination through geometric curvature rather than complex multi-element optics.
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 a uniformly lit appearance and reduces dark regions, enhancing the utilization of LEDs in lighting applications by ensuring consistent illumination patterns, especially when recess-mounted in ceilings.
Implementation Method 1
The first, second, third, and fourth total internally reflective surfaces receive light that passes through the first, second, third, and fourth sidewalls and reflect that light toward the base region
Implementation Method 2
The convex cavity bottom surface receives light from a light emitting diode and condenses the light
Implementation Method 3
The concave cavity bottom surface receives light from a light emitting diode and causes the light to diverge as it passes through the optic
Data Source
AI summary
A non-circular optic is described that includes a base region, the base region including a rim and an exit surface. The non-circular optic further includes a projection that projects from the base region, the projection including a cavity. The cavity includes an open end, a bottom surface, and first, second, third, and fourth sidewalls that extend from the open end to the bottom surface. A first, second, third, and fourth total internally reflective surfaces each extend from the open end of the cavity to the rim of the base region.