Low Profile LED Downlight Eyebrow with Dual Reflectors
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Solution Overview
Problem
Conventional downlighting systems are conspicuous, produce non-uniform illumination, and have high vertical attenuation, making them undesirable for commercial signage illumination.
Innovation Solution
A downlight assembly featuring an elongated eyebrow frame with an LED string and dual reflectors, including a primary reflector on the interior surface of the second wall and a secondary reflector as a winged rail, which improves illumination uniformity and intensity while maintaining a low profile and concealing the LED modules from view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional downlighting apparatus are used, then illumination is provided, but the apparatus are undesirably visible or conspicuous
Solution Approach 1:
The patent positions the LED light source in a horizontal plane extending from the wall rather than a vertical downward position. This dimensional repositioning allows the light source to be concealed behind the wall surface while still providing effective illumination, resolving the contradiction between providing illumination and concealing the visible light source.
2Ease of manufacture
If conventional downlighting apparatus are used, then illumination is provided, but the illumination pattern is undesirably non-uniform
Solution Approach 1:
The patent introduces a parabolic reflector as an intermediary optical element between the LED light source and the target wall surface. This reflector mediates the light distribution by capturing light from the LED and redirecting it in a controlled manner to achieve uniform illumination across the wall surface, resolving the non-uniformity issue.
3Ease of manufacture
If conventional downlighting apparatus are used, then illumination is provided, but vertical attenuation is undesirably high
Solution Approach 1:
The patent changes the illumination geometry from vertical downlighting to horizontal wall-washing. By positioning the LED horizontally and using a parabolic reflector to direct light along the wall surface, the system achieves extended vertical coverage with reduced attenuation compared to conventional vertical downlighting approaches.
4Object-affected harmful factors
If a low profile assembly is used, then the light source is concealed, but the illumination coverage may be limited
Solution Approach 1:
The patent uses a parabolic reflector as an optical intermediary that extends the effective illumination coverage beyond the physical footprint of the compact LED assembly. The reflector captures and redirects light to achieve extended vertical wall coverage while maintaining a low-profile concealed installation, resolving the contradiction between concealment and coverage area.
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 achieves a downlight wall wash with low lateral variation in intensity and extended vertical coverage, providing a high-quality, low-profile illumination that conceals the light source, enhancing both aesthetic and functional aspects of commercial signage.
Implementation Method 1
an LED string comprising a plurality of LED modules
Implementation Method 2
two or more reflectors including a primary reflector oriented at a first angle relative to the illuminated region and a secondary reflector oriented at a second angle relative to the illuminated region
Data Source
AI summary
A downlight eyebrow includes an elongated L-shaped structure including a first wall and a second wall forming a right angle. The downlight eyebrow may be installed at an upper edge of a vertical structure with the first eyebrow wall extending horizontally away from an upper edge of the structure and the second wall extending vertically downward from the first wall. A reflective material disposed on an interior surface of the second wall provides a primary reflector. A flange that extends from an intermediate point in the eyebrow, downward and away from the second wall, toward the vertical surface may provide a secondary reflector.