Unitary Folded Polymeric Light Shade Design

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Solution Overview

Problem

Polymer-based lighting fixtures face issues with unsightly gaps and seams between panels, weight addition from coupling hardware, and difficulty in modifying complex lighting designs due to the need for complete disassembly.

Innovation Solution

A light shade design featuring a top surface formed by alternating peak and trough folds, with a bottom surface that is a mirror image, allowing for a unitary polymeric sheet to be folded into a shape that covers a lighting element without visible joints, and can be suspended using mounting extensions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple panels are coupled together to form complex lighting structures, then the design versatility and geometric complexity are improved, but the number of visible seams and gaps increases, and the overall aesthetic quality deteriorates

Engineering Contradiction:

Improvedesign versatilityVSAvoidvisible seams and gaps

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent combines multiple panels into a single monolithic piece of polymeric material that is formed through folding and shaping processes. This merging eliminates the seams and gaps that would exist between separate panels while maintaining the ability to create complex geometric designs through the folded structure itself.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs curved and folded surfaces to create the lighting structure. By using continuous curved surfaces formed from the monolithic material, the design achieves complex geometries without visible joints, as the curvature itself becomes the defining feature rather than discrete panel edges.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Strength

If coupling hardware and adhesive are used to connect panels, then the structural integrity is improved, but the weight of the lighting fixture increases, and the aesthetic quality deteriorates due to shadows and dark spots

Engineering Contradiction:

Improvestructural integrityVSAvoidfixture weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent eliminates the need for separate coupling hardware by forming the entire structure from a single monolithic piece of polymeric material. The structural integrity is maintained through the inherent strength of the continuous material and the folded geometry, rather than through additional fasteners or adhesives that would add weight and create aesthetic defects.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes the flexibility and formability of polymeric material to create a thin-walled folded structure that maintains structural integrity through its geometry rather than through heavy fastening hardware. The material itself is shaped into the final form, eliminating the need for separate structural components.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If multiple panels are coupled together to form complex lighting structures, then the design versatility is improved, but the number of components and assembly steps increases, making modification difficult

Engineering Contradiction:

Improvedesign versatilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple panels into a single monolithic piece that is formed through folding processes. This reduces the number of discrete components from multiple separate panels to one integrated structure, significantly simplifying assembly and modification while maintaining design versatility through the folded geometry.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates the appearance of segmented panels through folding lines and creases in the monolithic material. The structure is divided into geometric sections by the folds themselves rather than by physical joints between separate pieces, maintaining the visual complexity of multiple panels while using a single continuous component.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If polymer-based panels are used instead of glass, then the cost and versatility are improved, but the appearance of seams and gaps becomes more noticeable

Engineering Contradiction:

Improvemanufacturing costVSAvoidvisible seams and gaps

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent manufactures the entire lighting structure from a single sheet of polymeric material through folding and shaping processes. This eliminates the seams and gaps that would be visible between separate panels, while maintaining the cost and manufacturing advantages of using polymer materials instead of glass.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10781996B2Ray design and manufacturing methods

Publication Date: 2020.09.22 3FORM

AI summary

A light shade can include a top surface formed by a plurality of adjacent, alternating peak and trough folds that define intervening facets, a bottom surface disposed opposite the top surface, and an edge surface transverse to and connecting the top surface and the bottom surface. The intervening facets can each be in the shape of a triangle with adjacent triangular facets sharing an edge. The shared edge can be one of a peak fold or a trough fold. One or more of the trough folds can have a plunge between the edge surface and an opposing side of the top surface. In an implementation, the light shade can be manufactured from a unitary polymeric sheet with the bottom surface being a mirror image of the top surface.