Textured LED Collimator Optic for Beam Diffusion Control
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Solution Overview
Problem
Existing semiconductor light-emitting devices, such as LEDs, often produce beams that are either too narrow due to excessive collimation or poorly collimated, limiting their optical performance when using total internal reflection (TIR) collimators and light extraction lenses.
Innovation Solution
The top surface of a collimating optic is textured with varying lenslets that provide different levels of diffusion or scattering, with areas above refractive lenses having lower optical power and areas above TIR surfaces having higher optical power, allowing for tailored beam diffusion based on the position and characteristics of the lenslets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a TIR collimator is used to redirect light into a tight beam, then beam collimation is improved, but the beam becomes too narrow with excessive collimation
Solution Approach 1:
The patent applies local quality by texturing only specific regions of the collimator optic. Areas above TIR surfaces have higher optical power texturing to increase diffusion, while areas above refractive lenses have lower or no texturing to maintain collimation. This localized differentiation resolves the contradiction by providing the right beam spread in the right places.
Solution Approach 2:
The collimator optic is segmented into different functional zones: regions above TIR surfaces, regions above refractive lenses, and transition areas. Each segment has tailored texturing characteristics that address specific local requirements, allowing the overall system to achieve balanced collimation without excessive narrowing.
2Ease of operation
If the beam is made too narrow through excessive collimation, then directional lighting is improved, but optical performance is limited
Solution Approach 1:
The patent changes the optical parameters (texturing density, feature size, depth) of the collimator surface to optimize performance. By adjusting these parameters in different regions, the system achieves the right balance between directional lighting and overall optical performance, preventing the beam from becoming too narrow.
Solution Approach 2:
The patent introduces dynamic control through adjustable texturing that can adapt to different operating conditions. The varying optical power across different regions allows the system to dynamically balance collimation and diffusion based on the specific light source characteristics and application requirements.
3Ease of manufacture
If uniform texturing is applied across the entire collimator surface, then manufacturing simplicity is improved, but beam diffusion cannot be tailored to different regions
Solution Approach 1:
The patent implements local quality by applying different texturing characteristics to different regions of the collimator. Areas above TIR surfaces receive higher optical power texturing for increased diffusion, while areas above refractive lenses receive lower optical power texturing. This regional differentiation achieves precise beam diffusion control while remaining manufacturable.
Solution Approach 2:
The patent adds spatial dimensionality to the texturing pattern, transitioning from uniform 2D texturing to 3D spatially-varying texturing with different optical powers in different regions. This dimensional enhancement enables tailored beam diffusion without significantly complicating the manufacturing process.
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 approach optimizes the beam collimation, achieving a balanced diffusion that enhances the optical performance by adjusting the beam spread according to the specific light source characteristics, improving the usability of light-emitting devices in applications like spot lamps.
Implementation Method 1
The top surface of a collimating optic is textured with varying lenslets that provide different levels of diffusion or scattering
Implementation Method 2
areas above refractive lenses having lower optical power and areas above TIR surfaces having higher optical power
Implementation Method 3
total internal reflection (TIR) collimators
Data Source
AI summary
A system can include a light emitting diode (LED) and a transparent structure disposed over the LED. The transparent structure includes a first surface that reflects light extracted from the LED and incident on the first surface. The transparent structure also includes an exit surface opposite the first surface. The exit surface includes a first area that is textured to diffuse light over a first angular range and a second area that is textured to diffuse light over a second angular range. The second angular range is wider than the first angular range.