Segmented Optical Device for Thin-Lens Light Collimation

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Solution Overview

Problem

Existing optical devices for modifying light distribution require thick collimating lens sections, complicating manufacturing and increasing production costs.

Innovation Solution

An optical device with a center portion comprising two successive lens sections and a reflector portion providing total internal reflection, where the ingress surfaces of the lens sections are designed to achieve collimation with thinner profiles, allowing for easier manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick collimating lens section is used, then sufficient collimation effect is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvecollimation effectVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The single thick collimating lens section is divided into two separate lens sections (first lens section and second lens section) with different functions. The first lens section handles light collection and the second lens section handles collimation, allowing each to be thinner and easier to manufacture while achieving the same overall collimation effect.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a new spatial arrangement where the second lens section is positioned adjacent to the first lens section, creating a multi-dimensional light path. This dimensional rearrangement allows the collimation function to be distributed across multiple thinner sections rather than requiring a single thick section.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If a thick collimating lens section is used, then sufficient collimation effect is achieved, but production cost increases

Engineering Contradiction:

Improvecollimation effectVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By segmenting the collimating function into two separate lens sections, each section can be manufactured thinner and cheaper. The first lens section collects light from the LED, and the second lens section collimates it, reducing material usage and manufacturing complexity compared to a single thick lens section.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If a single lens section is used, then device simplicity is maintained, but collimation effectiveness is insufficient

Engineering Contradiction:

Improvedevice simplicityVSAvoidcollimation effectiveness

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The lens system is segmented into two functional sections: the first lens section for light collection and the second lens section for collimation. This segmentation improves collimation effectiveness while maintaining reasonable device simplicity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges the functions of light collection and collimation into a single integrated optical device structure, where the first and second lens sections work together as a unified system. This combining approach achieves effective collimation without requiring separate complex components.

Inventive Principle:

Principle #5Merging (Combining)

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 enables effective light collimation while reducing the thickness of lens sections, simplifying manufacturing and potentially lowering production costs.

Implementation Method 1

a reflector portion surrounding the center portion and comprising a reflector surface configured to provide total internal reflection 'TIR'

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

The center portion comprises a first lens section comprising a first light ingress surface and a first light egress surface, and a second lens section successively with the first lens section and comprising a second light ingress surface and a second light egress surface

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS20250327560A1An optical device for modifying a light distribution and a method for manufacturing the same

Publication Date: 2025.10.23 LEDIL

AI summary

An optical device (201) comprises a center portion (203) and a reflector portion (204) surrounding the center portion and comprising a reflector surface (205) configured to provide total internal reflection. The center portion comprises a first lens section (206) and a second lens section (207) after the first lens section in a propagation direction of light. A projection of a light ingress surface (208) of the first lens section on a geometric plane (xy) perpendicular to a geometric line (z) through center of mass points of the first and second lens sections is smaller than a corresponding projection of a light ingress surface (210) of the second lens section on the geometric plane. As there are the two successive lens sections, a desired collimation effect can be achieved even if the lens sections are sufficiently thin from the viewpoint of manufacturing.