Rod Lens Light Module for Curing Illuminance
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Solution Overview
Problem
Lambertian light sources used in curing processes face inefficiencies due to wasted light energy when combined with lenses, as increasing lens size and proximity to the light source reduces light transmittance and concentration, thereby decreasing illuminance and increasing system volume and cost.
Innovation Solution
A light-emitting module comprising a light-emitting unit and a rod lens where the radial direction of the rod lens is parallel to the optical axis, with the distance between the lens axis and the light-emitting center greater than or equal to the focal length, allowing for efficient light concentration without enlarging the lens, thus maintaining high transmittance and reducing system volume and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the lens size is increased and the Lambertian light source is placed within the focal length of the lens, then all lights within a range of 120 degrees are able to enter the lens, but the penetration distance of the light in the lens is increased, which reduces the transmittance of the light in the lens and makes the light hard to be concentrated
Solution Approach 1:
The patent changes the optical parameters by using a micro-lens array with specific focal lengths and arranging light-emitting units at precise distances (greater than or equal to the focal length) to optimize light concentration without increasing lens size. This parameter optimization allows effective light guidance while maintaining compact dimensions and high transmittance.
Solution Approach 2:
The patent divides the optical system into multiple micro-lenses arranged in an array, where each micro-lens handles a specific angular range of light. This segmentation allows the system to capture and concentrate light from Lambertian sources effectively without requiring a single large lens, thus reducing overall system volume while maintaining high light utilization efficiency.
2Productivity
If the lens size is increased to concentrate all lights outputted from the light source, then more light can be captured, but the volume and cost of the curing system are increased
Solution Approach 1:
The optical system is segmented into multiple micro-lenses that collectively capture light from the Lambertian source. Each micro-lens focuses light from specific angular ranges, and their combined effect achieves high light utilization without requiring a large single lens, thus maintaining compact system volume while improving curing efficiency.
Solution Approach 2:
The patent transitions from a single-point light source model to a linear array of multiple light-emitting units, each paired with micro-lenses. This dimensional change allows the system to capture light from multiple angles simultaneously, achieving high productivity with a compact footprint by utilizing spatial arrangement in the array dimension.
3Quantity of substance
If the Lambertian light source is placed within the focal length of the lens, then all lights within a range of 120 degrees are able to enter the lens, but the light is hard to be concentrated and the illuminance applied to the surface for curing is reduced
Solution Approach 1:
The patent optimizes the distance parameter between light-emitting units and micro-lenses, setting it to be greater than or equal to the focal length. This parameter change ensures that light from Lambertian sources is properly focused by the micro-lenses, achieving both high light capture quantity and high concentration intensity for effective curing.
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 enhances the curing process efficiency by ensuring all light is concentrated on the other side of the rod lens, reducing energy waste and maintaining high transmittance, thereby improving the curing process efficiency and reducing the volume and cost of the curing system.
Implementation Method 1
The rod lens is adjacent to the light-emitting unit, and converges the light along an optical axis
Data Source
AI summary
A light-emitting module (1) includes a light-emitting unit (10) and a rod lens (20). The light-emitting unit (10) outputs a light (11). The rod lens (20) is adjacent to the light-emitting unit (10), and converges the light (11) along an optical axis (100). A radial direction of the rod lens (20) is parallel to the optical axis (100). A distance between an axis (21) of the rod lens (20) and a light-emitting center (12) of the light-emitting unit (10) along the radial direction is greater than or equal to a focal length of the rod lens (20) along the radial direction.