Reduced Glare LED Light Device Using Integrated Lens and Diffusing Layer
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Solution Overview
Problem
Existing LED light systems face issues with glare due to the intensity of light sources, particularly affecting safety for motorists at night, as previous solutions like angular refraction and reflector systems either fail to provide a seamless light source or result in light loss and increased complexity.
Innovation Solution
A reduced glare LED light device is designed with a larger surface area for LED energy dispersion, utilizing a layer of Mylar film, thin white plastic with precise openings, and a conventional lens with molded optics and a clear coating containing refractory particles to control light patterns and minimize glare.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If angular refraction with TIR lenses is used for each diode, then glare is reduced, but the light source becomes spotty and the assembly process becomes complex and expensive
Solution Approach 1:
The patent merges multiple individual TIR lenses into a single integrated lens structure with multiple optical zones. Each zone corresponds to a diode and provides the necessary angular refraction, but all zones are part of one unified lens rather than separate components. This consolidation maintains the glare-reducing optical functionality while eliminating the complexity of assembling multiple individual lenses and their associated mounting structures.
Solution Approach 2:
The integrated lens serves multiple functions simultaneously: it provides angular refraction for multiple diodes, creates a seamless light distribution pattern, and eliminates the need for separate mounting structures for each optic. The single lens structure universally addresses the optical requirements for all diodes in the array, simplifying both the optical design and assembly process.
2Object-affected harmful factors
If diodes are pulled up into a conventional reflector system, then glare is reduced by hiding the light source, but there is loss of light and beam control, and the fixture becomes bulky
Solution Approach 1:
The patent introduces an integrated lens as an intermediary optical element between the diodes and the external environment. Instead of using a reflector system that bounces light (causing losses), the lens directly shapes and directs the light from each diode through precise angular refraction. This intermediary lens maintains beam control and minimizes light loss while still achieving glare reduction through controlled light distribution.
3Object-affected harmful factors
If more diodes are used over a given array to gain softer light spread, then glare is reduced, but the cost increases
Solution Approach 1:
The patent applies local quality by creating different optical zones within the single lens, where each zone is optimized for its corresponding diode. The lens provides localized angular refraction tailored to each diode's position and orientation, creating a seamless overall light distribution. This approach achieves soft light spread through optical design rather than by simply adding more diodes, thereby controlling glare without increasing the quantity of diodes required.
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 significantly reduces glare while maintaining optical control, improving safety by providing a unified and pleasing light source, and is more cost-effective and simpler to assemble compared to previous systems.
Implementation Method 1
A layer of highly reflective Mylar film is placed over the circuit board
Implementation Method 2
The lens is covered with a clear coating with a small refractory particles suspended within the coating
Implementation Method 3
a clear coating with a small refractory particles suspended within the coating
Data Source
AI summary
A device for providing light including: a housing; an array of a plurality of LED lights mounted to the housing, wherein, when active, each LED emits a highest intensity beam of light along a primary axis and emits a lower intensity beam of light along a secondary axis; a lens mounted to the housing, the lens including an optic element corresponding to each of the plurality of LED lights, each optic element intersected by the primary axis of the corresponding LED light; and a translucent edge-light diffusing layer located between two or more of the plurality of LED lights, the edge diffusing layer is not intersected by the primary axis and is intersected by the secondary axis of the LED lights.