Non-imaging Optical Lens for Rectangular LED Light Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED-based lighting systems face inefficiencies in distributing light energy into high aspect ratio rectangular output patterns, requiring complex optics and multiple LEDs, which increases costs and power consumption.
Innovation Solution
A non-imaging optical lens apparatus with cylindrically shaped refractive and reflective surfaces, combined with a complex outer surface, is used to collect and redistribute light energy from wide output sources, such as hemispherical LEDs, to achieve a high aspect ratio rectangular output distribution with improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional LED lenses are used to concentrate light into narrower patterns, then light intensity is improved, but optical efficiency deteriorates when redistributing into wide rectangular safety patterns
Solution Approach 1:
The optical lens is divided into multiple distinct surfaces: a first surface (comprising front and rear portions) and a second surface. Each surface performs a specific function in the light redistribution process, allowing optimized control over light paths to achieve both intensity concentration and efficient rectangular pattern formation without energy loss.
Solution Approach 2:
The patent transforms light distribution from a conventional single-dimension concentration approach to a multi-dimensional redistribution system. The first surface operates in one dimensional plane to concentrate light, while the second surface redistributes it in orthogonal dimensions to form the rectangular safety pattern, achieving efficient two-dimensional light control.
2Manufacturing precision
If complex secondary optics are used to redistribute LED light into regulated safety patterns, then output pattern precision is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple optical functions into a single integrated optical lens. The first surface (with front and rear portions) and second surface are combined in one lens structure, eliminating the need for separate secondary optics and reducing overall device complexity while maintaining precise rectangular pattern output.
Solution Approach 2:
The optical lens is designed as a multi-functional element that simultaneously performs light concentration, redistribution, and rectangular pattern formation. This universal optical component replaces what would traditionally require multiple specialized optical elements, simplifying the overall lighting system.
3Illumination intensity
If multiple LED's are used to meet HAR output pattern requirements, then light output distribution is improved, but power consumption increases
Solution Approach 1:
The patent combines the functions of multiple LEDs and complex optics into a single optimized optical system. By using one LED with a specially designed optical lens that performs both concentration and rectangular redistribution, the system achieves the required light output distribution with reduced power consumption compared to multi-LED configurations.
4Ease of manufacture
If conventional LED packaging is used with through-hole electrical packages, then manufacturing simplicity is maintained, but optical flux per watt deteriorates
Solution Approach 1:
The patent transitions from conventional through-hole electrical packaging to surface-mountable LED devices. This parameter change in packaging technology enables superior heat removal from the diode junction, directly improving optical flux per watt while maintaining manufacturing efficiency through standard surface-mount techniques.
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 enhances optical efficiency, reduces power requirements, lowers operating temperatures, and significantly reduces costs, making high-performance LED lamps more accessible and improving vehicle safety.
Implementation Method 1
A non-imaging optical lens apparatus with cylindrically shaped refractive and reflective surfaces, combined with a complex outer surface, is used to collect and redistribute light energy
Implementation Method 2
A non-imaging optical lens apparatus with cylindrically shaped refractive and reflective surfaces, combined with a complex outer surface, is used to collect and redistribute light energy
Data Source
AI summary
A device having an inner surface with a combination of reflective and refractive surface facets swept about an axis of revolution perpendicular to the optical axis of the device. The outer surface has a non-planar, non-circular, non-spherical shape. This outer surface generates an appropriate intensity distribution in a direction generally parallel to the major axis of the output rectangle and may also distribute energy generally parallelly to the minor axis of the output rectangle as well.