Free-Form Lens Design for High-Efficiency Weaving Light Patterns
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Solution Overview
Problem
Existing lighting devices struggle to create desired weaving lighting effects efficiently due to light blocking by gobo's and high manufacturing costs of architectural meshes with integrated optical elements, which reduce luminous efficiency and limit design flexibility.
Innovation Solution
An optical device comprising lenses with cavities for solid-state lighting elements, featuring asymmetrical and symmetrical light distributions to produce parallel beams that intersect and create a weaving pattern with high luminous efficiency, using a configuration of lenses with curved and stepped regions for internal reflection, and optionally rotating lenses for alignment flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If gobo's are used to generate desired patterns, then the light pattern can be created, but the luminous efficiency is reduced due to light blocking
Solution Approach 1:
The patent removes the gobo component entirely and replaces it with free-form lenses that directly shape the light output. The lens design extracts only the necessary light shaping function while eliminating the light-blocking gobo, allowing light to pass through the entire optical path without obstruction and maintaining high luminous efficiency.
Solution Approach 2:
The free-form lens performs multiple functions simultaneously: it collimates light, shapes the beam profile, and creates the desired pattern all in a single optical element. This multi-functionality eliminates the need for separate gobo components, reducing light loss and simplifying the optical system.
2Illumination intensity
If architectural mesh with integrated optical elements is used, then weaving lighting effect can be created, but manufacturing cost increases and design flexibility is limited
Solution Approach 1:
The patent divides the lighting system into independent modular units, each containing an LED and a free-form lens. These modules can be individually manufactured and then assembled into various configurations to create different weaving patterns, reducing manufacturing complexity and increasing design flexibility compared to integrated mesh systems.
Solution Approach 2:
The system employs adjustable and reconfigurable optical modules that can be dynamically positioned and oriented to create different weaving patterns. This dynamic capability allows the same hardware to produce multiple design variations without requiring complex integrated mesh structures.
3Stability of the object's composition
If mesh covers light elements to integrate them, then structural integration is achieved, but emitted light is blocked and luminous efficiency decreases
Solution Approach 1:
The patent uses thin, transparent or translucent protective covers instead of opaque mesh structures. These thin films provide structural protection and integration while allowing maximum light transmission, eliminating the light blocking issue associated with traditional mesh covers.
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 solution enables the creation of aesthetically appealing weaving light patterns with high luminous efficiency, reducing manufacturing costs and aligning constraints, while maintaining efficient light projection and color mixing for enhanced aesthetic appeal.
Implementation Method 1
a pair of opposing internally reflecting side surfaces for constraining said beam within said predetermined width
Implementation Method 2
the curved region is shaped to generate a collimated beam portion along an optical axis
Implementation Method 3
the stepped region comprises a plurality of prismatic protrusions, each of said protrusions extending between said opposing internally reflecting side surfaces
Data Source
AI summary
Disclosed is an optical device (10) comprising a plurality of lenses (100) for projecting a plurality of parallel beams (202, 204) having a predetermined width towards an object area, wherein each lens comprises a lens body including a cavity (150) for housing a solid state lighting element (200); a pair of opposing internally reflecting side surfaces (130) for constraining said beam within said predetermined width; and a light exit surface delimited by said opposing side surfaces, the light exit surface comprising a curved region (110) extending from a first further side surface (141) extending between the opposing side surfaces and shaped to generate a collimated beam portion along an optical axis; and a stepped region in between the curved region and a second further side surface (142) extending between the reflecting side surfaces, wherein said steps are defined by a plurality of prismatic protrusions (120), each of said protrusions laterally extending between said opposing side surfaces. A luminaire including at least one such an optical device is also disclosed.