Freeform Lens Design for Uniform Illumination with Extended Source

Dan we', Kai Wang l , Sheng Liu l ,2,*

'Division of MOEMS,Wuhan National Laboratory for Optoelectronics, School of Optoelectronics Science & Engineering,
Huazhong University of Science & Technology, Wuhan 430074, China
2 Institute for Microsystems, School of Mechanical Science & Engineering, Huazhong University of Science & Technology,

Wuhan 430074, China

* Corresponding author, Tel: 86-13871251668, Fax: 86-27-87557074, Email: victor_liu63@126.com

Abstract
Nonuniform illumination caused by extended source is
one of the challenging points for high power Light-emitting
diodes (LEDs) especially for LED array applications. A new
design method to improve the uniformity of illuminance of
extended source is presented. To obtain high uniformity at
target plane, a feedback optimization method is introduced
including target plane girds, light source girds and target
plane and light source girds optimization algorithms. Monte
Carlo ray tracing simulation results demonstrate that our
feedback optimization algorithms are able to obviously
increase the uniformity of illuminance at target plane. The
uniformity increases from 0.53 to 0.9, 0.77 and 0.88 by our
three different optimization algorithms respectively. This
method would be a potential way in improving the uniformity
of illuminance at target plane with little light pattern
expansion.
1 Introduction
Light emitting diodes (LEDs), have increasing
applications in our daily life, such as road lighting,
backlighting for LCD display, headlamps of automotives,
interior and exterior lighting [1-3]. Multi-chips LED
packaging is one of the developing trends of LED packaging Fig. 1. Light pattern of circular symmetrical freeform lens
[1]. More and more LED modules integrated with multi-chips (a) with single chip LED module, and (b) with 3x3 LED array
such as 2x2 and 3x3. Compared with single chip LED module.
module, multi-chips LED packaging can emit more luminous In this paper, we propose a new freeform lens design
flux from single module and therefore is more suitable for method which can greatly improve extended source
high power LED lighting applications such as LED down uniformity with no obvious light pattern expansion. This
lamp, LED road lighting, LED headlamp of automotive, etc.. method can be expanded into three specific algorithms which
However, apart from the high luminous flux, the size of include optimizing target plane girds division, optimizing
multi-chips LED packaging raises new challenge for optical light source energy girds division, and optimizing both target
design. The light-emitting area of multi-chips LED packaging plane and light source energy girds division. It is expected
is much larger than that of single LED packaging. For that through any of these three algorithms, we can improve
example, the light-emitting area of 3x3 LED array package is the lighting performance deterioration of light pattern caused
9 times larger than that of single LED package and the ratio by size expansion of light source, achieving higher uniformity
of distance between source and lens to diameter of source will and more accurate control of the shape of light pattern.
be less than 5 [4]. Therefore, during the design of secondary
optics we should consider multi-chips LED package light 2 Problem statements
source as an extended source instead of a point source. If we Since one uniform and circular light pattern is commonly
apply point source design method [5-7] directly to extended adopted for most lighting applications, we will develop
source, the light pattern will deteriorate severely [7]. Fig. 1 algorithm for this application in this paper. As shown in Fig.
shows that one circular symmetrical freeform lens designed 2, an extended source with the size of 3mm X 3mm is placed
according to point source method with height of 7mm is at the plane and generates the Lambertian light intensity
applied to a single LED module and to a 3x3 LED array distribution curve (LIDC). A freeform lens designed by our
module respectively. We can find that both the shape and the feedback method is mounted closely on the extended source.
uniformity of light pattern deteriorate significantly due to the The distance between the freeform lens and the target plane is
expansion of the size of light source.

2011 International Conference on Electronic Packaging Technology & High Density Packaging 1085
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h and the radius of target plane is R. Refractive index of steps, and the rest steps are similar with point source design
polymethyl methacrylate (PMMA) is 1.49. method which we do not discuss in details.

Fig. 2. Schematic of design target of freeform lens for

extended source.
In this method, optimization of overall lighting
performance is to be achieved by adjusting target plane and
light source grids division and reconstruction the outside
surface of lens. Therefore, to prominence to our key issue, the
inner surface of the lens is designed as a spherical cone shape,
which will not change the transmission directions of the
incident light. Focus will be put on the construction of the
outside surface of the freeform lens. In this work, we will
present a practical design method of freeform lens to generate
a circular light pattern for extended sources with high
illumination performance.
3 Design methods
Feedback optimization design method of circular
symmetrical freeform lens for extended source is shown in
Fig.3. First of all, we build a freeform lens for point source Fig. 3. Design flow chart of circular symmetrical freeform
with circular symmetrical uniform light pattern. Since the lens feedback method for extended source.
construction method of freeform lens for point source has In the following, we specifically describe the extended
already been successfully applied in various products, we source freeform lens construction procedures.
describe the algorithm in brief as follows. We divide target
plane into grids with equal area and light source with equal (1) Construction of point source freeform lens.
energy. An energy mapping relationship is built between a
(2) Calculation of feedback optimized parameters.
couple of light source grids and target plane grids. Based on
After construction of point source freeform lens, we adopt
Snell's law, we are able to construct the freeform lens which
ray tracing method to simulate point source freeform lens
is suitable for the point source. Step 2, we apply the freeform
with extended source. Since light source intensity distribution,
lens designed by point source on the extended source and
the shape of lens and the target plane area are all circular
trace light transportation by optical software. As we expected,
symmetrical, illuminance distribution of horizontal axis
illumination results show that combination of extended source
direction is able to reflect the whole light pattern illuminance
with point source freeform lens will lead to seriously light
distribution on the target plane. In the following steps, we
pattern deterioration. We compare the deteriorated
only discuss the illuminance distribution along horizontal
illuminance distribution with the anticipated uniform
axis. We set the simulation results of illuminance with
illuminance, and obtain feedback ratios. Step 3, the feedback
extended source are E; At the same time, according to
optimization ratios are applied on target plane girds division
simulation results we can calculate the total flux of target
or light source girds division or apply on them both, and
therefore derive three different algorithms. In this method, plane <1> total_target is:
girds division will be adjusted according to feedback ratios <1> total_target == 17 X <1> total_source (1)
and are not equal division like point source freeform lens
Among them, 11 is the efficiency of freeform lens light
design method. Based on the optimized girds division, we
emitting, and <1> total_target is the total flux of target plane. The
rebuild energy relationship between light source and target
plane and reconstruct freeform lens. Step 4, we evaluate the target light pattern area is Starget=nR2 , where R is the radius of
simulation results the same way as Step 2. If the uniformity of the circular light pattern. Therefore, the average illuminance
illuminance on target plane satisfies our criterion, we of target plane is E av :
complete the feedback optimization; otherwise, we continue E == <1> total_target
our design until the freeform lens meets our requirement. In av (2)
Starget
this design method, feedback ratios acquisition, redivision of
girds, and energy relationship establishment are three key We use E av as the expected average illuminance of each girds.
When the division number of girds is large enough, we can

2011 International Conference on Electronic Packaging Technology & High Density Packaging 1086
realize uniform illuminance of the whole lighting area. With
extended source, the previous simulation results show that the
illuminance values of target plane at different position on the
light pattern are usually quite different from the average
illuminance value E av . It is expected that by changing the
target plane or light source girds division average illuminance
of each gird could gradually tum into E av and a uniform
illuminance of the whole target plane can be achieved.
Feedback parameter for each gird is set as k, which reflects
the difference between simulation result and expectation
value.
k.==~
E 1
(3)
av
Since we can only obtain limited illuminance values at the
target plane, they are probably not in accordance with target
plane gird division positions. In order to obtain k, at each
desired point on target plane, we adopt least square method to
fit k, and we obtain the relationships between coordinates r,
and k, , k, =f (rj) . By this method, we can get any points
located at the target plane along horizontal axis direction.
(3) Girds division of target plane and light source.
From illuminance definition equ.4, illuminance of each
gird can be changed by varying the area of each gird at the
target plane or the flux of each gird of light source or both of
them.
E == cD (4)
S
We set cfJj as flux of each gird of light source, and S, as area of
each gird at target plane. In the point source design method,
light source and the target plane are divided into equal girds
which means cfJj=cfJ o and Sj=So . We also set a, and b, as the
changing ratios of cfJj and S; Then, the flux of each changed
gird will be cfJj'=GjcfJj and the area of each changed gird at
target plane will be S, 'i-bS, . Therefore, illuminance of each
changed gird at target plane will be:
E.I==~
1 S,'
(5)
In order to realize uniform illumination, illuminance value at
each gird will approach to E av and the ideal situation is they
are equal as shown in equ.6.
t; ,== Eav (6)
Combination equ.4 and 5 we can obtain the following
equation:
k.==~ cDilSi cDilSi ~ target plane.
(7)
1 Ei I cD i 'I s, I aicDi I biSi ai
We know that k, can be obtained from simulation results and
the problem can be divided into three different situations: a)
when Gj=I and b> k, , the algorithm shows that light source
still use point source uniform division method and we only
optimize the target plane division by changing ratios which is
k, ; b) when b, =1 and a, =Ilki , the algorithm shows that the
target plane still use uniform division method and we only
optimize the light source by changing ratios which is II k.; c)
when a, i-I, b, i- 1 and ki = b, I a, , the algorithm shows that
both target plane and the light source are optimized by
2011 International Conference on Electronic Packaging Technology & High Density Packaging
changing ratios at the same time. In this paper, as an example,
we set a, = (II ki ) 0.5 and b, = ki 0.5
(4) Rebuild the energy relationship between light source
and target plane.
In the point source design method, light source and the
target plane are both divided into N equal parts. Each gird of
target plane has the same area So, and each gird of light source
has equal luminous flux cfJo. In this method, after optimization
of girds' division, each gird luminous flux of light source and
each gird area of target plane are changed into cfJj and S,
respectively. It is important to notice that during the first time
of feedback optimization, each gird of light source will be
changed into cfJj= GjcfJ o, and each gird of target plane will be
changed into Sj=bjSo. However, during the second time
optimization, changing ratios of a, and b, possess different
values from the first time. Meanwhile, each gird of light
source and that of target plane are optimized based on the first
time optimized result instead of the original point source girds
equal division situation. To easily illustrate and understand,
we introduce subscript j to represent the times of
optimization. Light source girds, target plane girds and
corresponding feedback changing ratios are expressed as
follows: cfJji' Sji, Gji and b.; For example, we use G23 to
represent the changing ratios of the second times optimization
applied on the third piece of light source.
According to light source energy division method, we can
obtain emitting angles ()ji of an optimized light source gird:
fJi I(B)sinBdB = t <1> ta
2ff ji = j i <1> j-li (8)
i=O i=O
Among them, cfJ Oj means before optimization the luminous
flux of each light source gird, in other words cfJo; ()jO
represents the first emitting light ray direction which is
vertical pointed and the value is o.
In the same way, we can calculate each gird's area after
optimization and the corresponding radius of each gird.
N N
Jrrj/ == L
i=O
Sji == L bjiSj-li
i=O
(9)
Among them, SOj denotes before optimization the area of each
gird which is So; rjO means the first emitting ray arrives at the
target plane and the value is O. By combining equ.8 and 9, we
can calculate light ray emitting angle ()jj after the jth
optimization and corresponding emitting point at target plane
with radius rji. In this way, we can build energy mapping
relationship between the newly divided light source and the
(5) Freeform lens for extended source construction.
According to the new energy mapping relationship
between light source and the target plane, we employ seed
curve method to build the circular symmetrical freeform lens.
(6) Ray tracing simulation and circulation feedback
optimization.
We analyze the light pattern illuminance of extended
source with the new designed freeform lens. If the evaluation
results satisfy our preset standards, we accept the design;
otherwise, we circulate more times to optimize the design
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until the results satisfy the illuminance requirements. In this
paper, we use UE as the evaluation standard, which expresses
the minimum and maximum illuminance variance.
U == E min (10)
E E
max

4 Design exam pies

In our analysis, a 3mm x3mm extended source is
introduced. The luminous flux of light source is 100 Im, Our
goal is by adding freeform lens to form a uniform circular
light pattern with radius of 1.73m. The distance between the
light source and the target plane is 1m and therefore the edge
ray emitting angle is 1200 • The height of the lens is 7mm with
PMMA material whose refractive index is 1.49. We divided
the light source and the target plane into 500 girds each and Fig. 4. Simulation results of target plane girds
choose 64 points along the horizontal direction at the target optimization algorithm.
plane. Based on these test points' changing ratios, a 10th
order polynominal function is introduced to fit the values and
obtain the function of kj=f(rj). In the following, we separately
use 1) target plane girds optimization algorithm;2) light
source girds optimization algorithm and 3) target plane and
light source girds optimization algorithm to optimize the
freeform lens design.
4.1 Target plane girds optimization algorithm
First of all, we design a freeform lens according to point
source design method. We use a 3mm x3mm LED extended
source as the light source and the simulation results of the Fig. 5. Freeform lens shaps of target plane girds
horizontal central axis is shown in Fig. 4. The central region optimization algorithm.
has a higher illuminance value and the illuminance value 4.2 Light source girds optimization algorithm
decreases gradually as it approaches to the edge. We mainly In this algorithm we only change the light source girds
consider a circular region with radius of 1.44 to evaluate the division, which means bj=1 and aj=l/kj. Light pattern
uniformity at the target plane and the illuminance uniformity illumination results are shown in Fig. 6. The results show that
UE is 0.53. after the first time of optimization, UE enhances into 0.58 and
When we only adjust the target girds division method the second and third time 0.76 and 0.77 respectively. By light
which means that aj=l, and bt-k; the light pattern illuminance source girds optimization algorithm, we can enhance
simulation results are shown in Fig. 4. Simulation results illuminance uniformity of extended source at target plane but
show that after the first time of optimization DE increases to it is not as uniform as the plane girds optimization algorithm.
0.6, and after the second time of optimization DE increases to From Fig. 7 we can find the shapes of two lenses, and the size
0.9. At this point, we realize a very uniform of illuminance. changing is not very obvious. It varies mainly at the bottom
After the third time of optimization, illuminance distribution area.
curve show little change compared with the second time of
optimization and UE is still 0.9. Before and after our
optimization algorithm the size of the lens are shown in Fig.
5, we can find that the shape of the lens are similar except that
after optimization the size of the lens are larger especially at
the top of the lens.

Fig. 6. Simulation results of light source girds

optimization algorithm.

2011 International Conference on Electronic Packaging Technology & High Density Packaging 1088

Fig. 7. Freeform lens shaps of light source girds
optimization algorithm.
4.3 Target plane and light source girds optimization algorithm
We also study the effect of optimizing the target plane and
the light source girds division at the same time. In this part,
we adopt a, = (1Ikj )o.5 , bj=kj o.5 , as shown in Fig. 8, after the
first time of optimization, UE increases to 0.64, and after the
second time of optimization it increases into 0.88, through
which we obtain uniform illumination. As shown in Fig. 9,
the optimized shapes of the lens are very similar with that in
target plane optimization algorithm.
Fig. 8. Simulation results of target plane and light source
girds optimization algorithm.
Fig. 9. Freeform lens shaps of target plane and light
source girds optimization algorithm.
S Conclusions
From the above simulation results, we know that these
three design methods of freeform lenses are able to enhance
the uniformity of light pattern with extended source and
therefore realize uniform lighting. Among the three methods,
target plane girds optimization algorithm is able to increase
the uniformity of lighting area and after the second time of
simulation UE increases to 0.9, but it shows a little light
pattern expansion. Target plane and light source girds
2011 International Conference on Electronic Packaging Technology & High Density Packaging
optimization algorithm is also able to enhance the illuminance
uniformity by less circulation times. After the second time of
circulation, the illuminance uniformity increases to 0.88, and
it also shows light pattern expansion effect. Compared with
the other two algorithms, light source girds optimization
algorithm is less able to enhance the uniformity of target
plane, and after the third time of circulation, UE increases to
0.77. However, it is capable of control the shape of light
pattern and there is less of light pattern expansion. Therefore,
the three algorithms have their own advantages and could be
applied into different situations. When we need high uniform
illumination of target plane we can choose algorithms 1 or 3,
and when we have strict requirements on light pattern
expansion, we can choose algorithm 2.
Acknowledgments
This work was supported by Nature Science Foundation
of China (NSFC) Key Project under grant number 50835005,
NSFC Project under grant number 50876038, High Tech
Project of Ministry of Science and Technology under grant
number 2009AA03AIA3 and Guang Dong Real Faith
Optoelectronics Inc.
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