Asymmetrical Illumination Shaping Structures for Compact Wall Lighting

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Solution Overview

Problem

Existing asymmetrical light beam illumination systems for flat or quasi-flat surfaces face challenges such as complex optical surface realization, large footprint, and increased production costs due to metallization requirements.

Innovation Solution

A device comprising a plurality of shaping structures, each with a first optical surface directing emergent beams onto a wall and a second optical surface for total internal reflection or transmission/refraction, arranged to achieve homogeneous illumination by averaging the beams from multiple structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a reflective shell with micro-facets is used to direct light beams, then the illumination direction can be controlled, but the manufacturing complexity increases significantly due to the large number of micro-facets requiring very low roughness and small edge radius

Engineering Contradiction:

Improveillumination direction controlVSAvoidoptical surface complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The reflective shell is divided into multiple discrete reflectors, each with a specific orientation. This segmentation allows each reflector to be simpler to manufacture while collectively achieving the desired illumination direction control through their arranged orientations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each reflector is oriented to direct light toward a specific target area or wall section. This local quality approach allows different parts of the illumination system to have different orientations optimized for their specific function, rather than requiring a uniformly complex micro-facet structure throughout.

Inventive Principle:

Principle #3Local quality

2Illumination intensity

If a reflective shell with many micro-facets is implemented, then light direction control is achieved, but the production cost increases due to metallization requirements and manufacturing complexity

Engineering Contradiction:

Improvelight direction controlVSAvoidproduction cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

By segmenting the illumination system into multiple discrete reflectors rather than one complex micro-facet shell, the manufacturing process is simplified. Each reflector can be produced using standard metallization techniques without requiring the extremely precise micro-facet fabrication, thereby reducing production costs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The discrete reflector design allows for simpler, potentially cheaper materials and manufacturing methods compared to a precision micro-facet shell. The reflectors can be produced more economically using conventional metallization processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Illumination intensity

If a reflective shell design is used to illuminate wall surfaces, then direct light can be limited to opposite walls, but the system occupies a large footprint that is not conducive to varied use

Engineering Contradiction:

Improvewall surface illuminationVSAvoidsystem footprint

Core Design Contradiction:

Illumination intensityVSArea of stationary object

Solution Approach 1:

The illumination system is divided into multiple discrete reflectors that can be arranged in a compact configuration. This segmentation allows the reflectors to be positioned closer together and oriented to achieve the desired wall illumination without requiring a large overall system footprint.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflectors are oriented in different spatial dimensions and angles to direct light toward wall surfaces. This multi-dimensional arrangement allows the system to achieve effective wall illumination while maintaining a compact footprint, as the light redirection occurs through angular orientation rather than through large physical distances.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution provides a compact, cost-effective illumination system with improved homogeneity and large angle dynamics, independent of the primary light beam quality, while avoiding complex optical surface manufacturing and large footprints.

Implementation Method 1

each shaping structure comprising at least one first optical surface configured to direct emergent beams in the direction of a wall to be illuminated

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

each shaping structure comprises a second optical surface configured to realize total internal reflection of the primary light beam

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS12222098B2Illumination system with lens projecting asymmetrical light beam

Publication Date: 2025.02.11 GAGGIONE SA

AI summary

A device for shaping a primary light beam, the shaping device including a plurality of shaping structures. Each shaping structure has at least one first optical surface configured to direct incident light beams in a desired direction, and a second optical surface configured to totally internally reflect incident light beams towards the first optical surface. An LED might provide the primary light beam, and includes collimating optics.