Multi-layer Polymeric LED Lens for Precision Light Control
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Solution Overview
Problem
Current LED light fixtures face challenges in achieving low-cost, energy-efficient, and high-precision secondary lenses for directing light, which impact the overall optical efficiency and manufacturing speed and accuracy.
Innovation Solution
A unitary optic member with multiple polymeric layers, including a first molded polymeric layer forming the non-lens portion and outermost layer of each lens portion, with a second layer overmolded within a pocket-space, utilizing different polymeric materials such as acrylic and cured liquid silicone resin, and optionally a third layer, to enhance light direction and reduce manufacturing time and distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-layer polymeric lens is used for secondary LED lensing, then manufacturing is simpler and faster, but manufacturing precision and optical accuracy are insufficient
Solution Approach 1:
The lens is divided into multiple polymeric layers, each with specific functions. The first layer provides structural support and basic optical properties, while the second layer provides the precise lens contour and optical accuracy. This segmentation allows each layer to be optimized independently, achieving high manufacturing precision without requiring the entire lens structure to be reworked for minor accuracy adjustments.
Solution Approach 2:
Different regions of the lens have different material properties and functions. The first polymeric layer uses a material optimized for structural integrity and manufacturing efficiency, while the second layer uses a material optimized for precise optical shaping. This local differentiation of material quality allows the lens to achieve high accuracy in critical optical regions while maintaining manufacturing efficiency overall.
2Manufacturing precision
If a multi-layer polymeric lens design is used to improve manufacturing precision, then lens accuracy improves, but manufacturing time increases due to multiple molding steps
Solution Approach 1:
The first polymeric layer is molded in advance with built-in pocket spaces that precisely define the locations and shapes of the lens regions. This preliminary structuring eliminates the need for time-consuming post-molding operations such as drilling, machining, or repositioning fixtures during subsequent molding steps. The pocket spaces are created as integral parts of the first layer, allowing the second layer to be directly molded into place without additional alignment or positioning time.
Solution Approach 2:
The second polymeric layer is molded directly into the pocket spaces of the first layer, creating a nested structure where one layer is embedded within the other. This nesting approach eliminates the need for separate assembly operations, as the layers are bonded together during the molding process itself. The nested design allows both layers to be manufactured in a single integrated process flow, minimizing the addition of manufacturing steps despite the increased structural complexity.
3Productivity
If thicker polymeric layers are used for molding, then manufacturing is simpler with fewer layers, but cooling time increases and manufacturing speed decreases
Solution Approach 1:
The lens manufacturing is segmented into multiple thinner polymeric layers instead of using a single thick layer. Each layer has a reduced thickness that allows for significantly shorter cooling times during the molding process. By dividing the total lens thickness into multiple segments (layers), the cooling time for each layer is proportionally reduced, thereby increasing overall manufacturing speed while maintaining the necessary structural integrity and optical performance.
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 multi-layer polymeric lens design improves light directionality, reduces manufacturing time and costs, and enhances the optical efficiency of LED light fixtures by allowing precise light control and faster cooling of thinner layers, addressing the need for cost-effective and accurate LED secondary lensing.
Implementation Method 1
a first molded polymeric layer forming the non-lens portion and the outermost layer of each of the lens portions... a second molded polymeric layer overmolded onto the first polymeric layer
Data Source
AI summary
A lens for directing light from an LED light source. The lens is formed by a plurality of layers and has a light-receiving inner-surface defining a pair of cavities. A portion of the inner-surface which defines one of the cavities is at least partially formed by an innermost layer of the plurality of layers. At least a portion of another of the plurality of layers extends inwardly between the pair of cavities. Another aspect of this invention is an optic member including a plurality of the lenses for directing light received from a plurality of spaced apart LED light sources.