Opaque Polycarbonate LED Diffuser for Glare Reduction
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Solution Overview
Problem
Conventional LED lamps with point light sources produce harsh glare and are aesthetically unpleasing due to the visibility of surface-mounted LEDs, and existing diffusers either reduce light transmission or fail to effectively hide the light source shape.
Innovation Solution
A chip-on-board LED lamp with a cylindrical body and an opaque polycarbonate lens containing irregular organic polymer particles, which scatters light to achieve a non-directional photometric distribution and hides the LED when engaged or disengaged, maintaining high light transmission and luminous efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If scattering particles are added to the diffuser to soften LED light and hide the light source, then the hiding power and light diffusion improve, but the light transmission decreases dramatically
Solution Approach 1:
The patent applies parameter changes by carefully controlling the particle size (0.5-10 microns), particle loading (3-30%), and refractive index matching of scattering particles in the diffuser. These parameter optimizations enable the diffuser to achieve both high hiding power and high light transmission simultaneously, resolving the technical contradiction between these two properties.
Solution Approach 2:
The patent uses composite materials by combining transparent plastic with specifically selected scattering particles (inorganic or organic) that have matched refractive indices. This composite structure allows the diffuser to maintain high light transmission while achieving effective light scattering and hiding power, overcoming the trade-off between these properties.
2Ease of manufacture
If pigments are added to the cover to increase hiding power, then the light source becomes better concealed, but the light transmission is dramatically reduced
Solution Approach 1:
The patent changes the approach from using pigments to using scattering particles with specific size parameters (0.5-10 microns) and refractive index properties. This parameter change enables achieving high hiding power through light scattering rather than absorption, thereby maintaining high light transmission while concealing the LED light source effectively.
Solution Approach 2:
The patent avoids using pigments that absorb light and instead uses refractive index-matched scattering particles that redirect light. This approach changes the mechanism from absorption-based hiding to scattering-based hiding, maintaining color neutrality and high light transmission while achieving the desired hiding power.
3Productivity
If the LED is made visible to provide bright directional light, then the luminous efficiency is high, but the glare becomes harsh and the appearance is aesthetically unpleasing
Solution Approach 1:
The patent introduces a diffuser as an intermediary component between the LED light source and the environment. This diffuser scatters the directional LED light into omnidirectional distribution, eliminating harsh glare while preserving luminous efficiency. The diffuser acts as a mediator that transforms the light distribution pattern without significant energy loss.
Solution Approach 2:
The patent transforms the light distribution from a directional pattern (1D/2D concentration) to an omnidirectional pattern (3D distribution) using the diffuser. This dimensional change in light distribution eliminates glare hotspots while maintaining overall luminous output, resolving the contradiction between efficiency and glare reduction.
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 hidden LED appearance with improved light dispersion and reflection properties, maintaining high luminous efficiency and omnidirectional light distribution while concealing the LED from view both when on and off, thus addressing the harsh glare and aesthetic issues of conventional LED lamps.
Implementation Method 1
The concentration of organic polymer particles in the polycarbonate material causes a visible haze to the surface of the polycarbonate material such that the lens portion appears opaque to a viewer
Data Source
AI summary
Embodiments of the present disclosure provide for a light emitting apparatus comprising a directional LED array and an opaque lens configured to disperse light in an omnidirectional output pattern while maintaining similar light dispersion and heat dissipation performance as that of translucent lenses. In accordance with various aspects of the present disclosure, the desired optical properties of the present light emitting apparatus may be enabled through the use of a lens constructed from a polycarbonate or polycarbonate blend material melt blended with a concentration of organic diffusion particles to comprise a thermoplastic matrix having a desired opacity and optical characteristics.