TIR Optic Cluster Layout for LED Color Mixing and Narrow Beams
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Solution Overview
Problem
Existing LED lighting panels face challenges in achieving effective color mixing while maintaining control over the angle of emission, particularly in color changing configurations and when reducing the size of optics.
Innovation Solution
The LED engine is configured to mix colors of multiple LEDs in a limited footprint by reducing the size of the optics, with the outer TIR surfaces maintained at a specific distance from the LEDs to control emission angle and fringe colors. The center of the TIR optics is fused to enhance color mixing, combining the advantages of discrete LED and LED cluster solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the size of TIR optics is reduced to improve color mixing, then color mixing distance is shortened, but control over emission angle distribution is diminished
Solution Approach 1:
The patent applies local quality by differentiating the TIR optic into two distinct zones: a first TIR surface for controlling emission angle and a second TIR surface for color mixing. This allows each region to be optimized for its specific function - the first surface maintains precise optical control while the second surface enables effective color mixing over shorter distances.
Solution Approach 2:
The TIR optic is segmented into functionally distinct surfaces - a first TIR surface and a second TIR surface - that perform different optical functions. This segmentation allows the system to simultaneously achieve both precise emission angle control and effective color mixing in a reduced footprint configuration.
2Manufacturing precision
If discrete LEDs with narrow beam angles are used, then beam angle control is improved, but color mixing performance deteriorates
Solution Approach 1:
The patent merges the advantages of discrete LEDs and LED clusters by integrating a multi-LED source with a unified TIR optic structure. The multiple LEDs are positioned within the TIR optic housing, allowing color mixing to occur while maintaining the narrow beam angle control characteristic of discrete LED solutions.
Solution Approach 2:
The TIR optic structure provides different optical functions at different locations - the first TIR surface controls the beam angle for each LED while the second TIR surface enables color mixing, allowing the system to simultaneously achieve both narrow beam control and good color mixing.
3Illumination intensity
If LED clusters with large optics are used to achieve good color mixing, then color mixing is improved, but the size of optics must be increased which reduces productivity
Solution Approach 1:
The patent achieves effective color mixing in a compact configuration by using a second TIR surface specifically optimized for color mixing. This localized color mixing region allows the system to achieve good color uniformity without requiring large optic sizes, thereby improving fixture density and productivity.
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 configuration enables shorter color mixing distances, precise control over emission angles, and reduced unmixed light beams near the edge of emission, resulting in improved color uniformity and beam control.
Implementation Method 1
a first total internal reflection (TIR) surface of the plurality of TIR optics, each of the plurality of TIR optics having a second TIR surface opposite the first TIR surface
Data Source
AI summary
Aspects of the present disclosure include a light emitting diode (LED) module including a plurality of LEDs, each of the plurality of LEDs being spaced apart from one or more neighboring LEDs by a spacing, a plurality of optics each disposed over a corresponding LED of the plurality of LEDs, each of the plurality of optics having a radius, and a plurality of LED chips disposed within the plurality of LEDs and each having a LED light emitting surface having one or more sides with a length, wherein a ratio of the spacing, the radius, and the length is configured to cause a light emitted from the LED engine to be narrower than 14 degrees and with a relative Cd/lm greater than 10 and with a measured application color uniformity of less than 0.005 Du1v1.