3D Optics With Internal Beam Forming for Custom Light Patterns
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Solution Overview
Problem
Existing lighting fixtures struggle to efficiently produce customizable beam patterns, particularly with LED-based systems, due to limitations in beam shaping capabilities.
Innovation Solution
The use of three-dimensional (3-D) optics with beam forming features, manufactured through techniques like 3-D printing or additive manufacturing, which incorporate internal structures or surface shapes to shape light beams into desired patterns such as narrow, wide, batwing, or asymmetric beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional beam shaping methods are used with LED lighting fixtures, then beam patterns can be produced, but customization flexibility and efficiency are limited
Solution Approach 1:
The patent transitions from 2D surface optics to 3D volumetric optics by incorporating internal beam forming features within the optic body. This dimensional change enables complex beam patterns to be achieved through internal structure geometry rather than requiring complex external optical assemblies, thereby improving customization flexibility while managing system complexity.
Solution Approach 2:
The patent utilizes 3D manufacturing processes to precisely control the geometry, position, and optical properties of internal beam forming features. By varying parameters such as feature shape, size, material composition, and spatial arrangement, a wide range of beam patterns can be customized without changing the overall optic structure, thus enhancing adaptability while maintaining manufacturing efficiency.
2Adaptability or versatility
If complex beam shaping optics are used, then various beam patterns can be achieved, but manufacturing difficulty and cost increase
Solution Approach 1:
The patent implements beam forming features as localized internal structures within specific regions of the optic. Each feature can be independently designed with specific optical properties (refractive index, absorption, scattering) to control light behavior in particular areas. This local quality approach allows complex beam patterns to be achieved through simple, manufacturable local modifications rather than requiring complex overall optic redesign.
Solution Approach 2:
By moving beam shaping functionality into the 3D interior volume of the optic rather than relying on complex 2D surface profiles, the patent enables a broader variety of beam patterns to be manufactured using standard 3D printing or additive manufacturing processes. This dimensional transition simplifies manufacturing while expanding beam pattern capabilities.
3Manufacturing precision
If non-planar surfaces are used for beam shaping, then beam patterns can be controlled, but dirt accumulation increases
Solution Approach 1:
The patent relocates beam forming functionality from the external non-planar surfaces to internal 3D structures within the optic body. This allows the external surfaces to maintain simple planar or smooth geometries that resist dirt accumulation, while the internal features perform the beam shaping function through their three-dimensional geometry and optical properties.
Solution Approach 2:
The internal beam forming features act as intermediaries between the incident light and the external environment. These internal structures control beam shaping without requiring complex external surface profiles, thereby mediating between the need for precise beam control and the desire for easy-to-maintain external surfaces.
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
Enables on-site and on-demand customization of beam patterns, enhancing lighting flexibility and reducing dirt accumulation through a planar top layer, thereby improving lighting efficiency and performance.
Implementation Method 1
The 3-D optic includes a first surface configured to receive incident light, a second surface positioned relative to the first surface and configured to emit a light beam having a shape
Implementation Method 2
The beam forming feature is an internal structure positioned between the first surface and the second surface
Data Source
AI summary
In an embodiment, there is provided a three-dimensional (3-D) optic for beam shaping. The 3-D optic includes a first surface, a second surface and a beam forming feature. The first surface is configured to receive incident light. The second surface is positioned relative to the first surface and is configured to emit a light beam having a shape. The emitted beam shape is related to the beam forming feature. The beam forming feature is formed by a 3-D manufacturing process.