Elimination of flux loss by optimizing the groove angle in modified Fresnel lens to increase illuminance uniformity, color uniformity and flux efficiency in LED illumination.

A Fresnel lens is an optical component that can be used to create systems more compact, cost-effective, and lightweight than those using conventional continuous surface optics. However, Fresnel lenses can usually cause a loss of flux efficiency and non-uniform distribution of illuminance due to secondary refraction by surface discontinuities, especially along the groove facet. We therefore proposed to modify a groove angle in the Fresnel lens and analyzed interrelation between the groove angle and multiple optical performances, such as flux efficiency and the uniformity of illuminance and color. The groove angle was optimized to maximize the uniformity and efficiency in the target viewing angle considering various weights of merit functions. Specifically, in our study, when the uniformity of illuminance had a little more weight than the flux efficiency (ratio of 0.6:0.4), final optimum groove angles of 24.7 degrees , 29.4 degrees , and 31.3 degrees were obtained at target viewing angles of 20 degrees , 30 degrees , and 40 degrees , respectively. We also fabricated a modified Fresnel lens with a groove angle of 29.4 degrees using UV-imprinting. The real optical performance of the fabricated Fresnel lens was then compared to that of a spherical lens.