Curved LED Modules for Uniform Illumination
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Solution Overview
Problem
Existing ceiling luminaires face challenges with inhomogeneous illumination and high manufacturing costs due to the need for multiple dedicated LED Modules for different luminaire geometries, which also results in increased tooling costs and laborious assembly processes.
Innovation Solution
A luminaire design featuring a plurality of identical, curved LED Modules with a curved PCB and lenses that emit a rotational symmetric batwing beam, allowing for uniform luminance across a wide range of luminaire geometries, reducing the diversity of Stock Keeping Units (SKU) and effectively using PCB material, while enabling the placement of electronic components within the luminaire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a large number of LEDs are mounted on a large PCB to achieve homogeneous illumination, then the illumination uniformity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The luminaire is divided into multiple modular LED modules, each containing a specific number of LEDs (e.g., 6, 12, or 24 LEDs) mounted on separate PCBs. These modules can be independently manufactured and then assembled into the final luminaire configuration, reducing the complexity of manufacturing large-scale LED arrays while maintaining illumination uniformity through proper module arrangement.
Solution Approach 2:
The patent describes LED modules that can be designed with universal applicability across different luminaire types and sizes. The modules use standardized mounting structures and optical components that allow them to function in various configurations (ceiling-mounted, wall-mounted, panel-mounted), eliminating the need to redesign PCB layouts for each application.
2Illumination intensity
If dedicated curved LED Modules are provided for inner and outer arrangements, then the illumination quality is improved, but the number of Stock Keeping Units increases
Solution Approach 1:
The patent proposes designing a universal LED module that can serve both inner and outer arrangements in the luminaire. The module uses identical curved PCBs with the same LED configuration that can be positioned in different locations within the luminaire structure, eliminating the need for separate dedicated modules for different spatial arrangements.
Solution Approach 2:
The patent allows for flexible positioning and configuration of LED modules within the luminaire structure. The modules can be dynamically arranged in different patterns (concentric circles, radial arrangements, or other configurations) depending on the specific luminaire design requirements, while using the same standardized module component.
3Illumination intensity
If large integral lens plates are used to widen LED intensity distribution, then the light distribution is improved, but the tooling costs and machine requirements increase
Solution Approach 1:
Instead of using a single large integral lens plate, the patent divides the optical system into multiple smaller lenses or lens elements. Each LED or small group of LEDs has its own lens or a small array of lenses, which can be manufactured using standard optical tooling rather than requiring expensive large-scale lens fabrication equipment.
Solution Approach 2:
The patent applies different optical characteristics to different parts of the luminaire. Each LED module position has optimized lensing tailored to its specific role in the overall illumination pattern, allowing local optimization of light distribution without requiring a single complex large lens system.
4Illumination intensity
If a curved PCB with LEDs is used to achieve uniform luminance, then the illumination uniformity is improved, but the PCB material usage increases
Solution Approach 1:
The patent optimizes the PCB design by placing LEDs and optical components only where needed to achieve uniform luminance distribution. The curved PCB layout is carefully designed to match the required illumination pattern, avoiding unnecessary PCB material in areas where LEDs would not contribute to uniform luminance.
Solution Approach 2:
The patent uses a moderate number of LEDs strategically positioned on the curved PCB rather than maximizing LED density. By optimizing the LED arrangement and using appropriate optical lenses, the system achieves uniform luminance with a reasonable number of LEDs, avoiding excessive PCB material consumption.
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 solution achieves cost savings by reducing the number of LED Module types needed, optimizing PCB material usage, and ensuring uniform illumination, even in luminaires with low thickness, while allowing for efficient placement of electronic components within the luminaire.
Implementation Method 1
a number of N LEDs (15) are mounted on a main surface of the curved PCB (14)
Implementation Method 2
each LED has a respective lens positioned on an optical axis of an associated LED die accommodated in a cavity in a lens base of the lens
Data Source
AI summary
A luminaire (1) comprising identical curved LED Modules (13, 13′, 13″) in an inner and an outer arrangement of LED Modules. Said LED Module comprising a curved PCB (14) having a main surface and a number of LEDs (15) arranged thereon. The LED Module has width W and is curved with its main surface extending in a plane Q. The LED Module extends over a circle with a radius Rc, wherein 200 mm<=Rc<=450 mm, and extends over an angle a over said circle, wherein 36°<=a<=72°. The number of LEDs is in between 3 and 150. Each LED (15) has a respective doughnut like shaped lens to render the LED during operation to emit a rotational symmetric batwing beam with a maximum intensity Imax of the batwing beam at an angle 13 with 60°<=13<=80° with said optical axis, and a FWHM in the range of 15-30°.