Adjustable Light Shaping Visor for LED Fixtures
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Solution Overview
Problem
The high cost and inefficiency of die casting multiple types of visors for LED lighting fixtures, combined with wind resistance issues and logo durability problems, hinder the scalability and performance of large area lighting solutions.
Innovation Solution
A modular light shaping system comprising a semi-circular snoot and a bowl-shaped brow, both die-cast from lightweight materials, which can be adjusted and rotated to create various configurations, reducing the need for multiple die casting tools and minimizing wind resistance through a low Effective Projected Area design, while allowing for durable logo integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple types of visors are manufactured using die casting to achieve specific light shaping, then the light control precision is improved, but the manufacturing cost increases due to the need for multiple expensive die casting tools
Solution Approach 1:
A single die casting mold produces a visor component with multiple functional surfaces: an outer surface for light shaping and an inner surface with integrated logos. This universal mold design eliminates the need for separate molds for different visor types, reducing manufacturing tooling costs while maintaining precise light control capabilities through the shaped outer surface.
Solution Approach 2:
The logo application process is merged with the die casting manufacturing process itself. Logos are embossed or engraved directly into the mold cavity, so the logo feature is created simultaneously with the visor geometry in a single casting operation. This integration eliminates separate logo application steps and reduces the need for additional tooling.
2Ease of manufacture
If traditional logo stickers are applied to visors, then the branding is achieved, but the logo durability deteriorates due to fading and tearing from wind and sun exposure
Solution Approach 1:
The mechanical adhesive bonding system (stickers with adhesive) is replaced with a metallurgical bonding system where logos are embossed or engraved directly into the die casting mold. This creates a permanent, integral part of the visor structure that cannot fade or peel, as the logo becomes part of the metal itself rather than a separate applied layer.
Solution Approach 2:
The logo features are prepared in advance during the mold making process, with logos embossed or engraved into the mold cavity before the actual visor production begins. This preliminary action ensures that every visor produced from this mold will have the same durable logo integrated into its structure, eliminating the need for post-manufacturing logo application.
3Manufacturing precision
If visors are designed with traditional shapes to achieve light shaping, then the light control is improved, but the wind resistance increases due to higher Effective Projected Area
Solution Approach 1:
The visor employs a curved, aerodynamic shape with a rounded leading edge and a tapered trailing edge. This curved geometry allows wind to flow smoothly over the surface, reducing turbulence and pressure drag. The curvature maintains the necessary light shaping profile while minimizing the Effective Projected Area that intercepts wind, thus reducing overall wind resistance compared to flat or angular visor designs.
4Ease of manufacture
If aluminum materials are used for die casting visors, then the manufacturing cost is reduced, but the wind resistance increases due to higher material density
Solution Approach 1:
The visor is designed as a thin-walled, hollow structure with internal ribs for reinforcement. This segmentation approach uses minimal material volume while maintaining structural integrity through the ribbed design. The thin walls reduce overall mass, and the hollow interior creates a lightweight structure that is easier to install and less susceptible to wind load, while aluminum die casting provides the necessary strength-to-weight ratio.
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
The modular system enables efficient light control and reduced wind resistance, achieving cost savings and improved durability by allowing hundreds of visor variations with minimal die casting tools and maintaining logo visibility over time.
Implementation Method 1
The snoot can efficiently reflect light that would normally be absorbed by a visor.
Implementation Method 2
The present invention provides a light shaping solution which consists of 2 or more pieces which are die cast from aluminum, magnesium, or similar materials
Data Source
AI summary
A light shaping apparatus consisting of two or more components which may be die cast from aluminum, magnesium, or similar materials that are meant to be attached to existing LED venue lighting fixtures. These components are designed so that they can be rotated and adjusted on the fixture circumference/edge. A semi-circular snoot flares out slightly from the outer edge of the fixture to reflect light that would normally be absorbed by a visor. The snoot may include a reflector on its inside surface. The snoot has connection points that mate with the fixture. The snoot also has connection points which allow it to be connected to a semi-circular bowl spaded brow adapted for cutting into the beam of light and block some of light emitted from the fixture. The brow is preferably one piece and has multiple sets of thin shear lines cast into it such that the length of the brow can be modified by breaking off material along the shear lines.