Thermally Structured LED Optical Element for Uniform Illumination
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Solution Overview
Problem
Existing optical elements for LEDs suffer from inhomogeneous light distribution and color irregularities due to the wide angular emission of LEDs, leading to unsightly bright spots and brightness transitions, which are not effectively addressed by current scattering structures that cause light loss and glare.
Innovation Solution
A thermally processed optical element with a light exit surface featuring a continuous, wave-like scattering structure divided into sub-areas with different geometries, created using a laser to control light refraction and emission, ensuring a smooth transition between zones to minimize unwanted scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional scattering structures are used to address inhomogeneous light distribution, then light loss and glare increase, but illumination uniformity is not effectively improved
Solution Approach 1:
The patent applies local quality by creating different scattering structures in different regions of the optical element. The scattering structures have varying densities and geometries matched to the local light emission characteristics of the LED, with higher scattering density in regions where LEDs emit more laterally to compensate for the inhomogeneous distribution without causing excessive light loss or glare.
Solution Approach 2:
The patent changes the parameters of the scattering structures, including size, shape, density, and distribution patterns, to optimize light redistribution. By adjusting these parameters locally across different regions, the patent achieves uniform illumination while minimizing light loss compared to conventional uniform scattering structures.
2Illumination intensity
If conventional scattering structures are used to address color irregularities, then glare increases, but color uniformity is not effectively improved
Solution Approach 1:
The patent applies local quality by tailoring the scattering structure characteristics to specific regions where different LED combinations are located. By matching the scattering properties to the local color emission patterns, the patent achieves color uniformity across the illuminated surface without creating glare that would occur with uniform scattering structures.
Solution Approach 2:
The patent replaces conventional mechanical or chemical surface treatments with laser-based structuring to create precise scattering patterns. This substitution enables better control over scattering properties and reduces unwanted glare while achieving color uniformity.
3Ease of operation
If LED light is directed using physical refraction properties, then light direction control improves, but inhomogeneous illumination and color irregularities arise
Solution Approach 1:
The patent combines refraction-based light direction control with locally adapted scattering structures. The scattering structures are positioned and configured in different regions to compensate for the inhomogeneous illumination and color irregularities produced by refraction, achieving both good light direction control and uniform illumination.
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 provides a high-quality, uniform illumination with precise control over light output, reducing light loss and glare while enabling targeted adjustment of illumination patterns, including graphical information display.
Implementation Method 1
with the aid of a laser, wherein the structure is divided into at least two sub-regions whose respective structures have a different geometry
Implementation Method 2
created by remelting the optical element or a tool used to produce the optical element with appropriate shaping
Implementation Method 3
Lens systems that direct the light in the desired direction using physical refraction properties have proven particularly advantageous
Implementation Method 4
The shape of the lens body 110 is designed such that these light rays are totally reflected at the outer surface 114
Data Source
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Figure 5a~5b
AI summary
The invention relates to an optical element (1) for influencing the light emission of illuminants, in particular for influencing the light emission of one or more LEDs (200), consisting of a light-transmissive material and comprising at least one surface region (7), which serves as light-refracting light-entrance face or light-exit face of the optical element (1). The surface region (7) has a structure (10) which was created by thermal processing the optical element (10) or a tool used to produce the optical element (1), with corresponding shaping, e.g. an injection molding tool. Said structure (10) is divided into at least two partial regions (101, 102...)the respective structures having a different geometry, said structures steadily merging into each other on common borders of the partial regions.