Flexible Lens Assembly with Curved Reflectors for Uniform LED Illumination
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Solution Overview
Problem
LED light fixtures with LED arrays mounted flat on the back surface facing the lens suffer from pinpoint high intensity light issues, leading to pixelization, uneven light distribution, and visually unpleasing shadows due to the close light source to lens distance, making it difficult to achieve even illumination and aesthetic appeal.
Innovation Solution
The use of side-facing LED arrays with curved reflectors and optical film light modifying elements, including diffusion particles and prismatic film strips, to distribute light more evenly and reduce brightness hotspots, combined with refraction features on the lens to mask the LED presence and enhance visual appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If LED arrays are mounted flat on the back surface facing the lens, then the light source to lens distance is reduced, but this causes pinpoint high intensity light issues, pixelization, and uneven light distribution
Solution Approach 1:
The patent applies curved reflectors instead of flat surfaces to redirect and distribute light more evenly. The curvature of the reflector surfaces helps to diffuse the pinpoint high intensity light from the LED arrays, reducing pixelization and creating more uniform illumination across the lens surface.
Solution Approach 2:
The patent introduces optical film light modifying elements as intermediaries between the LED arrays and the lens. These elements include diffusion particles and prismatic film strips that modify the light path, scatter the concentrated light, and distribute it more evenly across the optical surface, thereby reducing hotspots and pixelization.
2Volume of moving object
If LED arrays are mounted close to the lens, then the luminaire size is reduced, but this creates visually unpleasing shadows and pixelization
Solution Approach 1:
The patent applies different optical properties to different regions of the lens system. Refraction features are strategically positioned and configured with varying densities and geometries to mask the LED presence in specific areas while maintaining overall light distribution. This local variation in optical characteristics allows the system to maintain compact size while achieving visually pleasing results.
Solution Approach 2:
The patent uses refraction features that create visual effects to mask the LED arrays. These features manipulate light paths to hide the discrete LED sources, creating a more uniform visual appearance from the front, thereby improving aesthetic quality without increasing size.
3Device complexity
If flat mounting is used for LED arrays, then device complexity is reduced, but light distribution uniformity deteriorates
Solution Approach 1:
The patent employs curved reflectors that, while adding some geometric complexity, maintain relatively simple mounting structures. The curvature is achieved through forming processes that do not require complex assembly, while effectively distributing light to improve illumination uniformity.
Solution Approach 2:
The patent uses composite optical films combining diffusion particles with prismatic structures. This composite approach achieves superior light distribution uniformity through a single integrated element rather than multiple complex components, thereby maintaining ease of manufacture while improving optical performance.
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 configuration improves light distribution, reduces pixelization, and enhances the visual aesthetic by creating a more uniform and pleasing light pattern, increasing luminaire efficiency while maintaining cost-effectiveness.
Implementation Method 1
diffusion particles and prismatic film strips, to distribute light more evenly and reduce brightness hotspots
Implementation Method 2
prismatic film strips, to distribute light more evenly and reduce brightness hotspots, combined with refraction features on the lens
Data Source
AI summary
In an example embodiment, a flexible light fixture may be provided. The example embodiment may comprise a reflector panel comprising two substantially parallel opposing outer flanges and a flexible central portion, wherein the distance between the opposing outer flanges may be X. The example embodiment may also comprise a lens with two opposing edges wherein each opposing edge may be configured with an attachment feature configured for attachment to corresponding opposing outer flanges of the reflector panel, and wherein the distance between the opposing edges of the lens may be a distance Y, wherein distance Y may be less than distance X. When the opposing outer flanges of the reflector panel are compressed laterally together a distance that is at least distance Y and engaged by the corresponding lens attachment features, the flexible central portion of the reflector panel may be engaged in a curved compressed state.