Hybrid TIR Lens and Diffuser for Uniform Color Mixing
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Solution Overview
Problem
Conventional LED-based lighting systems face challenges in producing high-power, narrow beam light sources with uniform color mixing, as they often require large emitters and reflector housings, making it difficult to achieve efficient light distribution and color uniformity.
Innovation Solution
A hybrid lens system incorporating a total internal reflection (TIR) lens and a diffuser, configured to form a lighting apparatus with a multiple-LED emitter, providing a narrow beam angle spot light output with improved brightness and uniformity of color mixing, using an optical body member with a cylindrical cavity and a diffuser made of PMMA, which is fused together to create an integrated lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional approaches use large emitters and reflector housing to generate high power, then power output is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the TIR lens and diffuser into a single integrated optical element, eliminating the need for separate reflector housing and reducing overall device complexity while maintaining high power output capability
Solution Approach 2:
The integrated optical element performs multiple functions simultaneously: it provides total internal reflection for beam shaping, diffuses light for uniform color mixing, and focuses light for high power output, replacing what would traditionally require multiple separate components
2Power
If conventional approaches use large emitters to achieve high power, then power output is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The patent merges the TIR lens and diffuser into one integrated element that can be manufactured as a single piece, avoiding the complexity and cost of assembling multiple precision components while achieving high power output
3Ease of operation
If conventional designs are used, then simplicity is maintained, but uniform color mixing is difficult to achieve
Solution Approach 1:
The patent integrates the diffuser function within the TIR lens structure, ensuring uniform color mixing is achieved through the inherent optical path design rather than requiring complex external diffusing systems
Solution Approach 2:
The diffuser portion of the integrated optical element acts as an intermediary that evenly distributes light from multiple LED emitters before it exits the lens, achieving uniform color mixing across the beam
4Shape
If a very large secondary TIR lens is used with large emitters, then narrow beam angle is achieved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent combines the TIR lens and diffuser into a single integrated optical element, eliminating the need for very large secondary lenses while maintaining narrow beam angle capability through the unified optical design
Solution Approach 2:
The patent modifies the optical parameters of the integrated element to achieve narrow beam angles without requiring large physical dimensions, optimizing the balance between beam control and manufacturability
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 hybrid lens system achieves a 5-degree spot beam with uniform color and high brightness, effectively addressing the limitations of conventional systems by providing efficient light distribution and color mixing, suitable for high bay and stage lighting applications.
Implementation Method 1
The outer surface is shaped to provide total internal reflection (TIR) for light from a light source
Implementation Method 2
a diffuser that has a curved shell configured for being disposed over the light source and is configured to fit inside the cavity at the lower end of the optical body member
Data Source
AI summary
A lens system includes a TIR (Total Internal Reflection) lens and a diffuser. The lens has an optical body member including an upper end, a lower end opposite the upper end, and an outer surface. The outer surface is shaped to provide total internal reflection for light from a light source. An upper surface extends in a series of steps from the upper end to a first interior portion of the optical body member. A substantially cylindrical cavity extends from the lower end to a second interior portion of the optical body member. A middle portion separates the first and second interior portions and has a flat upper surface and a curved lower surface. The diffuser has a curved shell configured for disposing over a light source and configured to fit inside the cylindrical cavity of the optical body member, the diffuser having a circular rim fused to the lower end of the optical body member.