Tiled Micro-Optic Beam Shaping for LED Arrays
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Solution Overview
Problem
Existing beam shaping optics for LED lighting are bulky, expensive, and fail to achieve a small beam spread with high optical efficiency, particularly when using arrays of LEDs, resulting in aesthetic issues and reduced performance.
Innovation Solution
A beam shaping system comprising an array of units with a central refracting area, an intermediate TIR area, and an outer TIR area, featuring contoured surfaces with prismatic elements that provide efficient light collimation and shaping, allowing for increased optical efficiency and reduced beam spread by optimizing the angles of the prismatic elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional TIR collimators are used for light collection and collimation, then the beam shaping function is achieved, but the optical element occupies a large volume and is expensive
Solution Approach 1:
The patent employs thin-film micro-optics with microstructured surfaces that provide the same beam shaping functionality as conventional bulky TIR collimators. The thin-film structure reduces the volume significantly while maintaining the optical performance through carefully designed micro-features on the film surface that control light propagation.
Solution Approach 2:
The patent modifies the geometric parameters of the optical element by transitioning from a single bulky component to a tiled array of micro-structured units. The micro-structure geometry, tile arrangement, and surface contours are optimized to achieve the desired beam shaping while minimizing volume.
2Illumination intensity
If an array of LEDs with conventional collimators is used to increase light output, then the total light output is sufficient, but the shower-head impression creates aesthetic issues
Solution Approach 1:
The patent merges multiple individual collimator units into a unified tiled structure that presents a planar, homogeneous surface. The individual LED units with their respective micro-optics are arranged and integrated such that the overall structure appears as a single aesthetic unit rather than a collection of separate components, eliminating the shower-head impression.
Solution Approach 2:
The patent applies different local optical properties to different regions of the tiled structure. Each tile is optimized for its specific position in the array, with micro-structure variations that ensure uniform light output characteristics across the entire surface, creating a consistent aesthetic appearance while maintaining high total light output.
3Shape
If thin-film micro-optics are tiled to achieve a planar appearance, then the aesthetic issue is resolved, but achieving small beam spread with high optical efficiency remains difficult
Solution Approach 1:
The patent divides the beam shaping function into multiple segmented micro-optic tiles, each handling a portion of the light from corresponding LED units. The segmentation allows for optimized light control at the micro-scale while maintaining the macro-scale planar appearance. Each tile's micro-structures are designed to collimate and shape light effectively, and the collective arrangement achieves the desired small beam spread with high overall optical efficiency.
4Reliability
If the number of prismatic elements and their angles are optimized, then the beam spread is reduced and optical efficiency is increased, but the manufacturing complexity increases
Solution Approach 1:
The patent optimizes the geometric parameters of the prismatic elements, including the number of elements per tile, the angles of the prismatic faces, and the overall tile geometry. These parameter optimizations are balanced against manufacturing capabilities to achieve the desired beam spread and optical efficiency while maintaining practical manufacturability through standard fabrication processes.
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 system enhances optical efficiency and collimation performance, reducing the beam spread while maintaining aesthetic appeal by using a tiled structure with optimized prismatic elements, allowing for effective light processing from multiple LEDs.
Implementation Method 1
a central area for providing a beam passing function by refracting light from a light source beneath the central area
Implementation Method 2
an intermediate area for providing a beam shaping function via total internal reflection (TIR) of light from the light source beneath the central area
Implementation Method 3
an outer area for providing a beam shaping function via total internal reflection (TIR) of light from the light source beneath the central area and also providing total internal reflection of light from a light source beneath the central area of an adjacent beam shaping unit
Data Source
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AI summary
A beam shaping system is for example for use over an array of light sources. An array of beam shaping units is arranged in a general plane, each beam shaping unit comprising a central refracting area, an intermediate total internal reflection area for processing of light from a light source beneath the central area, and an outer total internal reflection area for processing light from the nearest light source and an adjacent light source. This outer area essentially extends the useful size of the adjacent beam shaping unit to improve the beam shaping performance and/or the optical efficiency.