Grid Lamp 2D Reflector Cell Array LED Positioning
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Solution Overview
Problem
Existing grid lights face challenges in achieving smooth light distribution patterns due to manufacturing tolerances and precision requirements, especially when neck openings are larger than LEDs, leading to undesirable edges and bumps in light distribution.
Innovation Solution
A grid light design where each reflector cell has a semiconductor light source positioned laterally differently relative to its neck opening, forming a regular arrangement, which smoothes the light emission pattern and reduces sensitivity to manufacturing variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the neck opening is only slightly larger than the LED, then the light distribution pattern is smoother, but high precision is required for the shape and arrangement of the reflector cell and positioning of LEDs
Solution Approach 1:
The patent applies asymmetry by intentionally offsetting the LED from the center of the neck opening. Instead of positioning the LED at the geometric center, it is placed at a specific lateral offset position that creates an asymmetric light distribution pattern. This asymmetric positioning compensates for the edges and bumps that would otherwise appear in the light distribution, achieving smooth light output without requiring extremely tight manufacturing tolerances on the reflector cell geometry.
2Manufacturing precision
If the neck opening is significantly larger than the LED, then manufacturing precision requirements are reduced, but the light distribution pattern exhibits undesirable edges and bumps
Solution Approach 1:
The patent applies local quality by varying the LED positioning strategy across different reflector cells in the grid. Specifically, alternating reflector cells have their LEDs positioned at different lateral offsets (e.g., offset in one direction for some cells, offset in the opposite direction for adjacent cells). This local variation in positioning creates complementary light distribution patterns that, when combined across the entire grid, cancel out edges and bumps, achieving smooth overall light output while allowing larger neck openings with relaxed manufacturing tolerances.
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 design results in a well-defined light distribution pattern with reduced impact from manufacturing tolerances, providing a smoother far-field emission and improved precision in light control.
Implementation Method 1
having a plurality of semiconductor light sources in the area of the neck openings
Implementation Method 2
flat LED lights with reflector cells arranged in a pattern or grid
Data Source
Figure 1
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Figure 4
AI summary
The louver light fitting (11) has multiple reflector cells (12), each of which has a neck opening (15) and a light outlet opening (16), and multiple semiconductor light sources (17) in the region of a respective corresponding neck opening (15). For at least two of the reflector cells (12), lateral positions (P) of the semiconductor light sources (17) differ relative to the respective neck openings (15), and a plurality (G1) of the different lateral positions (P) which are present in the reflector cells (12) has a uniform arrangement. A method is used to produce a louver light fitting (11), said method having at least the following steps: providing multiple reflector cells (12), each of which has a neck opening (15) and a light outlet opening (16); arranging multiple semiconductor light sources (17) in the region of corresponding neck openings (15) at positions (P) which are lateral relative to the corresponding neck openings (15) such that a plurality (G1) of the lateral positions (P) form a uniform arrangement.