Double-Skinned Optically Transmissive Housing for SSL Luminaires

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Solution Overview

Problem

Solid-state lighting (SSL) devices face challenges in replicating the luminous output of traditional light sources, leading to glare and increased manufacturing costs due to the need for complex beam shaping measures like reflective coatings or textured surfaces.

Innovation Solution

A double-skinned optically transmissive housing with a cavity between its inner and outer surfaces allows for easy insertion of components like reflective foils or thermally conductive members, which can shape the luminous output without adding bulk, and can be manufactured using cost-effective polymers and 3-D printing techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If reflective coatings are applied to the light source-facing surfaces of the housing to shape the luminous distribution, then the optical efficiency is enhanced, but the manufacturing cost increases and the production time is extended

Engineering Contradiction:

Improveoptical efficiencyVSAvoidmanufacturing cost and production time

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The patent changes the optical parameters of the housing material itself by using optically transmissive polymer with specific refractive index and light-guiding properties, replacing the need for additional reflective coatings while maintaining optical efficiency

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The housing structure provides its own optical functionality through the light-guiding properties of the optically transmissive polymer material, eliminating the need for separate reflective coating components and making the system self-sufficient

Inventive Principle:

Principle #25Self-service

2Object-affected harmful factors

If textured reflector surfaces are used to minimize glare effects, then the glare is reduced, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improveglare effectsVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent modifies the optical parameters of the housing material by selecting optically transmissive polymer with specific light scattering and diffusing properties that inherently reduce glare without requiring textured surfaces

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses standard optically transmissive polymer materials that can be easily manufactured through conventional molding processes, replacing complex textured surfaces with simpler, more cost-effective material selection

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Illumination intensity

If additional beam shaping components are added to the housing, then the luminous distribution is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveluminous distributionVSAvoidnumber of components

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The housing structure serves multiple functions simultaneously: it provides mechanical support, thermal management, and optical beam shaping through the light-guiding properties of the optically transmissive polymer, eliminating the need for separate beam shaping components

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the structural housing with optical beam shaping functionality by using optically transmissive polymer material that inherently guides and shapes light, merging what would traditionally be separate components into a single integrated structure

Inventive Principle:

Principle #5Merging (Combining)

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 enables the creation of SSL luminaires with customizable luminous distributions at lower costs, improving optical performance and reducing glare while maintaining a sleek design.

Implementation Method 1

The optically transmissive housing may be made of a polymer or polymer blend and may make use of the light-guiding effect to shape the luminous distribution produced with the luminaire

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

a reflective coating may need to be applied to the light source-facing surfaces of the housing in order to shape the luminous distribution produced with the luminaire

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS11112085B2Lighting device housing, luminaire and method of manufacture

Publication Date: 2021.09.07 SIGNIFY HOLDING BV

AI summary

A housing (10) for a lighting device is disclosed. The housing comprises an elongate base region (21) and opposing elongate sidewalls (23) extending from opposite elongate sides of the elongate base region towards respective terminal ends (24), wherein each of the opposing elongate sidewalls (23) has an optically transmissive inner surface (11) separated from an outer surface (13) by a distance of 5 millimeters or less to form a cavity (15) for housing a reflective foil or a thermally conductive member. The inner surface (11) extends across the elongate base region (21), and it comprises a recess (25) in the elongate base region (21) for housing a light engine (31). Also disclosed is a luminaire (1) including such a housing (10) and a method of manufacturing such an optically transmissive housing (10).