Dual Cylindrical Reflector System for Linear Lamp Illuminators
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Solution Overview
Problem
Existing linear lamp illuminator systems face inefficiencies due to cylindrical and paraboloid reflectors, which either waste light, are expensive, or produce undesirable beam patterns, and refractive elements can separate light colors, making them unsuitable for machine vision and surveillance applications.
Innovation Solution
A dual reflector system comprising a primary and secondary generally cylindrical reflector, oriented to collimate light in orthogonal planes, with adjustable positions and shapes, including parabolic and flexible reflective materials, to efficiently direct light from a linear light source into a focused beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a cylindrical reflector is used to collimate light, then the beam width in one plane is reduced, but the beam width in the orthogonal plane becomes very wide causing light waste
Solution Approach 1:
The patent applies a second cylindrical reflector oriented perpendicular to the first reflector. This adds another dimensional control element that collimates light in the orthogonal plane, converting the wide beam problem into a controlled narrow beam in both planes simultaneously, thereby reducing light waste while maintaining beam width control.
2Illumination intensity
If a cylindrical fresnel lens is added to improve collimation, then beam control improves, but the lens becomes heavy and expensive due to long focal length and large aperture requirements
Solution Approach 1:
The patent replaces the heavy refractive fresnel lens with reflective surfaces. The second cylindrical reflector performs the collimation function that would otherwise require a large aperture fresnel lens, eliminating the need for heavy glass or plastic materials while achieving the same optical effect through reflective geometry.
3Illumination intensity
If refractive elements are used for collimation, then beam formation improves, but color separation occurs due to dispersion which is undesirable for optical sensors
Solution Approach 1:
The patent substitutes refractive optical elements with reflective surfaces. Reflection does not cause chromatic dispersion like refraction does, so the dual cylindrical reflector system maintains color integrity while still achieving effective beam formation and collimation, making it suitable for optical sensor applications.
4Loss of energy
If a paraboloid reflector is used to capture most light, then light collection efficiency improves, but the reflector diameter becomes large and expensive for long flashlamps
Solution Approach 1:
The patent divides the light collection and collimation function into two separate cylindrical reflectors oriented perpendicular to each other. Each reflector handles one plane of light control, allowing for a more compact overall design compared to a single large paraboloid reflector, while still capturing and directing most of the light effectively.
5Loss of energy
If some paraboloid reflector configurations are used, then light capture improves, but a doughnut beam pattern is produced which is undesirable for imaging applications
Solution Approach 1:
The patent uses two cylindrical reflectors oriented in orthogonal planes to control light distribution. This dual-plane approach produces a more uniform beam pattern compared to single-reflector systems, eliminating the doughnut pattern problem while maintaining effective light capture through the perpendicular reflective surfaces.
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 dual reflector system enhances light collection efficiency, reduces illuminator volume, and improves illumination uniformity, producing a compact, cost-effective, and high-quality light source suitable for machine vision and surveillance, with improved beam control and reduced color dispersion.
Implementation Method 1
a primary generally cylindrical reflector having a primary focal axis and oriented to collimate light in a first plane
Implementation Method 2
a secondary generally cylindrical reflector having a secondary focal axis and oriented to collimate light in a second plane
Data Source
Figure 1a~1b
Figure 2~4
Figure 5~6
AI summary
The present invention provides an illuminator system comprising a dual reflector system and a linear light source. The dual reflector system comprises a primary and secondary generally cylindrical reflector, which collimate light from a linear light source in two planes. The linear light source may comprise many light emitting devices, and may emit light in a strobe or continuous fashion. The reflectors may be of many cylindrical shapes, and may include additional mirror segments to capture light otherwise not collimated. Further, the reflectors may be in various configurations of position and orientation with respect to one another, and may be adjustable in this respect. The system is more efficient than existing illuminators, is compact, all reflective (no colour), lightweight, simple and inexpensive to manufacture. The system has applications to many fields including machine vision, surveillance, spectroscopic inspection of materials, and converting linear light sources into rectangular beam spot lights.