LED Array Steering via Transparent Thermal Sheets

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Solution Overview

Problem

Existing luminaire designs face limitations such as reduced optical efficiency, non-uniform aggregate beam, limited flexibility in adjusting beam shape, and loss of efficiency due to shadowing from electrical connections and heat-spreading elements, as well as cross-talk during beam steering.

Innovation Solution

The design features an array of LEDs supported by a transparent heat-conducting sheet or cantilevered arms that minimize light blockage, allowing for improved efficiency and flexibility in beam steering, with the LEDs positioned in the focal plane of concave mirrors, and the use of sub-arrays of LEDs to steer and broaden the aggregate beam without mechanical actuation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional electrical connections and heat-spreading elements are used to support LEDs, then structural support and thermal management are achieved, but light blockage and shadowing occur reducing optical efficiency

Engineering Contradiction:

Improveoptical efficiencyVSAvoidsupport structure design

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent uses thin transparent heat-conducting films or sheets to support the LED array and conduct away heat. These thin films minimize light blockage compared to traditional bulky heat sinks and electrical connection structures, thereby maintaining high optical efficiency while providing necessary thermal management and structural support.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent introduces transparent heat-conducting adhesive layers or films as intermediaries between the LED array and the support structure. These intermediary layers conduct heat away from the LEDs while being transparent to light, eliminating the shadowing problem caused by traditional opaque heat sinks and electrical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If mechanical actuation is used to steer the beam, then beam direction control is achieved, but device complexity and noise increase

Engineering Contradiction:

Improvebeam steering controlVSAvoidmechanical actuation system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces mechanical actuation systems with electronic control of LED sub-arrays to achieve beam steering. By selectively activating different groups of LEDs within the array, the aggregate beam direction can be changed electronically without any moving parts, eliminating mechanical complexity and noise while maintaining full beam steering capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements dynamic beam steering through electronic reconfiguration of active LED sub-arrays. The system can rapidly change beam direction by electronically switching which LED groups are active, providing dynamic control without mechanical movement. This allows for fast, noise-free beam steering responsive to control signals.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If LED arrays are positioned to maximize beam control, then lighting flexibility is improved, but shadowing from support structures increases

Engineering Contradiction:

Improvebeam shape controlVSAvoidoptical efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent employs thin transparent heat-conducting films as support structures for the LED arrays. These films are sufficiently transparent that they do not create significant shadows or block light paths, allowing the LED arrays to be positioned for optimal beam control and flexibility without sacrificing optical efficiency through shadowing losses.

Inventive Principle:

Principle #30Flexible shells and thin films

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 enhances optical efficiency, reduces perceivable artifacts from shadows, and allows for complex emission patterns with improved beam control and reduced physical dimensions, power consumption, and noise.

Implementation Method 1

an array of concave mirrors that collimate the light

Methodology Applied

Scientific EffectCollimation: Reflection

Implementation Method 2

an array of LEDs supported by a transparent heat-conducting sheet

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10563844B2Configurable luminaire with light sources variably oriented with respect to an array of concave mirrors

Publication Date: 2020.02.18 LUMINII LLC

AI summary

An array of LEDs is supported by a support mechanism that both supports conductors leading to the LEDs and sinks heat from the LEDs. The support mechanism may be a transparent heat-conducting sheet or an array of cantilevered arms at different angles that support the LEDs and sink heat. This reduces the blockage of light. The LEDs are positioned generally in the focal plane of an array of concave mirrors that collimate the light. The LEDs and array of mirrors are translatable with respect to one another to steer the aggregate light beam to customize the emission. The LEDs may be variably oriented with respect to the associated mirror apertures so as to create different light beams emitted from different ones of the mirrors.