Free-form thin lens design with light scattering surfaces for practical LED down light illumination

The free-form optical quasilens surface technology was utilized to develop and design a solid transparent plastic optical lens for the LED down light with the narrow angular light distribution requirement in the LED lighting applications. In order to successfully complete the mission, the precise mid-field angular distribution model of the LED light source was established and built. And also the optical scattering surface property of the Harvey BSDF scattering model was designed, measured, and established. Then, the optical simulation for the entire optical system was performed to develop and design this solid transparent plastic optical lens system. Finally, the goals of 40 deg angular light distribution pattern defined at full width half maximum with glare reduced in the areas of interest and the optical performance of nearly 82% light energy transmission optics were achieved for the LED down light illumination.