Integrated Lens-Reflector Structure for Space-Efficient Recessed Lighting
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Solution Overview
Problem
Recessed lighting fixtures face space constraints while requiring enhanced functionality and optical performance.
Innovation Solution
A recessed lighting luminaire design incorporating a rounded corner upper reflector with a flange and a semi-transparent convex lens, integrated with an ultrasonic weld, optimized for space efficiency and light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate lens and reflector components are used, then ease of manufacture is improved, but device complexity and space usage increase
Solution Approach 1:
The patent combines the lens and reflector into a single integrated component made from a single piece of thermoplastic material. The reflector portion and lens portion are formed as one unified structure through injection molding, eliminating the need for separate components and their associated assembly operations. This merging reduces device complexity while maintaining manufacturing efficiency through a single-shot molding process.
Solution Approach 2:
The single piece component performs multiple functions simultaneously: the reflector portion directs light from the LED, the lens portion focuses and distributes the light pattern, and the integrated structure provides mechanical support and positioning. This multi-functionality within a single component reduces overall device complexity while maintaining ease of manufacture through standardized molding processes.
2Ease of manufacture
If traditional separate lens and reflector components are used, then ease of manufacture is improved, but space consumption increases
Solution Approach 1:
By merging the lens and reflector into a single integrated component, the patent eliminates the space required for separate components and their assembly interfaces. The single piece structure allows the light path to transition directly from the reflector surface to the lens surface without gaps or mounting hardware, minimizing the overall axial length and volume of the recessed lighting fixture.
Solution Approach 2:
The lens portion is effectively nested within the reflector structure, with the light path flowing continuously from the LED through the reflector surface and into the lens. This nested arrangement optimizes space utilization by eliminating dead space between components and allowing the optical elements to share the same structural envelope.
3Volume of moving object
If single piece integrated design is used, then space usage is minimized and optical performance is optimized, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes parameter changes in the molding process, specifically using a thermoplastic material that can be selectively crystallized or modified in different regions during injection molding. This allows the creation of complex optical surfaces with precise light distribution characteristics within a single piece structure, achieving space minimization without requiring assembly of multiple components.
Solution Approach 2:
The invention employs composite material properties by using a thermoplastic material that combines optical clarity for the lens portion with reflective or light-diffusing properties for the reflector portion. This single material system can be engineered to provide both optical functions simultaneously, reducing the need for multiple materials and assembly steps while maintaining design complexity for optimized space usage.
4Illumination intensity
If single piece integrated design is used, then optical performance is optimized by reducing light leakage, but manufacturing complexity increases
Solution Approach 1:
The integration of lens and reflector into a single piece structure eliminates gaps, seams, and interfaces where light leakage could occur. The continuous material structure ensures that light follows the intended optical path from the LED through the reflector and lens without escaping at component boundaries, optimizing illumination performance while the single-shot molding process keeps manufacturing relatively simple.
Solution Approach 2:
The molding process parameters are controlled to ensure proper optical properties in different regions of the single piece component. By adjusting crystallization parameters, material flow, and cooling rates during injection molding, the patent achieves precise control over light distribution characteristics and eliminates light leakage paths that would require complex assembly operations to prevent.
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 design minimizes space usage and optimizes optical performance by reducing light leakage and enhancing light distribution, while maintaining structural integrity and functionality.
Implementation Method 1
The lens 120 is joined with the upper reflector 118 with an ultrasonic weld 302
Implementation Method 2
a lens 120 with a substantially rectangular shape integrated with the substantially rectangular box of the upper reflector 118, the lens 120 includes a lens box with an open top and a bottom of the lens box being a semi-transparent convex material
Data Source
AI summary
A recessed lighting luminaire component that includes a reflector integrated with a lens is described herein. The reflector may have a square or round top opening, the walls of the reflector widening as the walls extend downward to a flange, the walls continuing below the flange in a square or round box. A square or round lens is integrated with the square or round box of the reflector, the square or round lens includes a lens box with an open top and a bottom of the lens box being a semi-transparent convex material, where walls of the lens box and the walls of the reflector are joined, perhaps with an ultrasonic weld, the flange being of circular shape extending outward from the reflector, the flange including a plurality of tabs, the flange configured to mount inside of a recessed lighting luminaire housing.