RPI ID:
2023-047-201

Innovation Summary:
This invention introduces a novel optic design for LED lighting systems featuring a dual-lens structure with planar external surfaces and internal nonplanar refractive surfaces that define an internal cavity. The internal surfaces are engineered using light-energy mapping techniques to refract incident light and produce a target output distribution tailored to specific illumination applications. The cavity, which may contain air, is bounded by freeform refractive surfaces that are optimized based on source parameters and target illuminance goals. Each lens structure is manufactured using three-dimensional (3D) printing, enabling precise customization and streamlined production.

Challenges / Opportunities:
Traditional refractive optics with contoured external surfaces are prone to lumen depreciation due to environmental contamination, reducing lighting performance over time. This invention addresses that issue by using flat external surfaces, minimizing dirt accumulation and simplifying assembly. The internal cavity design allows for advanced control of light distribution without compromising optical efficiency. The method and system are scalable and adaptable to various lighting geometries and applications.

Key Benefits / Advantages:
✔ Flat external surfaces reduce lumen depreciation and simplify cleaning
✔ Internal cavity design enables precise light control
✔ Freeform refractive surfaces tailored via light-energy mapping
✔ Compatible with LED sources and various target geometries
✔ Manufactured using 3D printing for design flexibility and cost efficiency
✔ Supports high uniformity and application-specific illuminance

Applications:
• LED lighting systems for architectural, industrial, and consumer environments

Keywords:
Optics, LED lighting, 3D printing, refractive lens, light-energy mapping, internal cavity

Intellectual Property:
US Issued Patent: US12379092B2