Tuned Composite Optical Arrangement for LED Arrays
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Solution Overview
Problem
LEDs in warning and signaling lights have limited light output, requiring multiple LEDs in arrays, which complicates design and introduces cooling challenges, with wide-angle light often being wasted due to its emission pattern.
Innovation Solution
An optical assembly with a linear array of LEDs, a concave reflective trough, and an elongated lens that redirects wide-angle light into a narrower beam, utilizing medial reflecting surfaces to partially and fully collimate light, ensuring it contributes to the desired illumination pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple LEDs are arranged in arrays to meet photometric requirements, then the light output is sufficient, but the device complexity and cooling requirements increase
Solution Approach 1:
The patent combines multiple LEDs into a linear array configuration where their individual light contributions are merged to achieve the required photometric output. The LEDs are positioned in close proximity with their optical axes aligned in a common plane, creating a unified light source that meets illumination requirements while maintaining a compact structure.
Solution Approach 2:
The patent transitions from conventional point-source LED arrangements to a linear array configuration, adding spatial dimensionality to the light source. By arranging LEDs in a line with their optical axes in a common plane, the system achieves extended illumination coverage and enhanced light output without proportionally increasing device complexity.
2Illumination intensity
If multiple LEDs are arranged in arrays to meet photometric requirements, then the light output is sufficient, but the cooling requirements increase
Solution Approach 1:
The patent combines the thermal management functions for multiple LEDs into a unified cooling structure. The linear array configuration allows heat sinks to be integrated along the LED array, efficiently dissipating heat from multiple diodes through shared thermal pathways and reducing overall cooling requirements.
Solution Approach 2:
The patent extends the cooling solution into the spatial dimension by implementing linear heat sink structures that run parallel to the LED array. This dimensional approach to thermal management allows heat dissipation along the length of the array, reducing hot spots and improving overall thermal efficiency compared to point-source cooling.
3Area of stationary object
If wide angle light from LEDs is emitted, then the light coverage is broad, but the light efficiency is reduced due to wasted light
Solution Approach 1:
The patent applies different optical control strategies to different angular regions of LED emission. The reflector and lens systems are specifically designed to redirect wide-angle light (which would otherwise be wasted) into the desired beam pattern, while maintaining control over narrow-angle light. This local optimization of light redirection improves overall light efficiency by capturing and utilizing previously wasted wide-angle emission.
Solution Approach 2:
The patent converts the harmful effect of wide-angle light emission (which causes light waste and reduced efficiency) into a beneficial resource. By incorporating reflectors and lenses that specifically target and redirect wide-angle light into the desired illumination pattern, the system transforms what was previously wasted light into useful illumination, thereby improving light efficiency while maintaining broad coverage.
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
Enhances light efficiency by redirecting wide-angle light into a focused beam, maximizing usable light output and reducing waste, while maintaining efficient heat management in compact designs.
Implementation Method 1
The elongated lens is configured to redirect light emitted from the array of LEDs (and not incident upon the reflecting trough) from its emitted trajectory into imaginary planes parallel with the first plane
Implementation Method 2
The reflective trough redirects wide angle light (light not passing through the elongated lens) from a range of emitted trajectories into a range of reflected trajectories closer to the first plane
Data Source
AI summary
An LED optical assembly includes a linear array of LEDs, longitudinal reflecting surfaces along each side of the array and medial reflecting surfaces between the LEDs. The longitudinal reflecting surfaces include surfaces of rotation centered on the optical axis of each LED interspersed with linear reflecting portions defined by curves projected along a linear focal axis of the assembly.