Adjustable Optics for Customizable LED Beam Patterns
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Solution Overview
Problem
Existing LED fixtures with multiple small light sources require separate optics and tooling for each beam type, limiting flexibility and increasing costs due to the inability to easily vary light distribution and intensity.
Innovation Solution
A system with individually positionable optics, such as reflectors and refractive lenses, allows for the creation of composite beams with customizable shapes and intensities by rotating or adjusting the optics, enabling a small set of optics to produce a variety of beam patterns, reducing inventory and lead time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate optics are used for each beam type, then beam distribution control is achieved, but device complexity and inventory requirements increase
Solution Approach 1:
A single optic design is made multi-functional by allowing it to be positioned at multiple discrete angles (e.g., 0°, 45°, 90°, 135°) relative to the LED array. This enables one optic type to produce multiple beam patterns (spot, flood, intermediate) that would traditionally require separate optics, thereby reducing inventory complexity while maintaining adaptability.
Solution Approach 2:
The optic mounting mechanism is designed to be adjustable rather than fixed, allowing the optic to be dynamically repositioned to different angular positions. This dynamic positioning capability enables a single optic to perform multiple functions, reducing the need for separate static optics for each beam type.
2Adaptability or versatility
If multiple optics types are maintained for different beam patterns, then beam pattern variety is achieved, but manufacturing and inventory costs increase
Solution Approach 1:
Instead of developing multiple separate optic designs for different beam patterns, a single universal optic design is created that can be positioned at different angles to produce various beam patterns. This reduces the number of development cycles, tooling requirements, and inventory SKUs needed while maintaining beam pattern variety.
Solution Approach 2:
The beam pattern is controlled by changing the angular position parameter of the optic rather than changing the optic design itself. This parameter-based control approach simplifies manufacturing since only one optic design needs to be produced, while still achieving beam pattern variety through positional adjustment.
3Ease of operation
If fixed optic positions are used, then manufacturing simplicity is maintained, but light distribution control flexibility is reduced
Solution Approach 1:
The mounting mechanism incorporates discrete adjustable positions that allow the optic to be set at specific angles (e.g., 0°, 45°, 90°, 135°). This provides operational flexibility for light distribution control while maintaining manufacturing simplicity through standardized positioning features and discrete adjustment steps.
Solution Approach 2:
The continuous range of possible optic angles is segmented into discrete, standardized positions. This segmentation allows for simplified manufacturing with standardized components while still providing sufficient flexibility for different lighting applications through the available discrete angle options.
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
This approach provides precise control over light distribution, reducing glare and spill light, and enabling 'pixel by pixel' control of illumination, increasing versatility and reducing costs by allowing a small set of optics to cover a wide range of lighting needs.
Implementation Method 1
Each light source may include its own reflector which is oriented in various directions, providing a beam pattern
Implementation Method 2
Each light source may include its own refractive lens which is oriented in various directions, providing a beam pattern
Data Source
AI summary
An apparatus, method, or system of lighting units comprising a plurality of lighting elements, such as one or more LEDs, each element having an associated optic which is individually positionable. In embodiments of the present invention, one or more optics are developed using optimization techniques that allow for lighting different target areas in an effective manner by rotating or otherwise positioning the reflectors, refractive lenses, TIR lenses, or other lens types to create a composite beam. The apparatus, method, or system of lighting herein makes it possible to widely vary the types of beams from an available fixture using a small number of inventoried optics and fixtures. In some cases, by using a combination of individual beam patterns, a small set of individual optics would be sufficient to create a majority of the typical and specialized composite beams needed to meet the needs of most lighting projects and target areas.