LED Projector Lens Matrix with Reflective Sheets for Beam Shaping
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Solution Overview
Problem
Conventional LED projectors face challenges in varying light beam directionality and intensity distribution, requiring multiple projectors for large area illumination, complex assembly, and lack of standardization, making it difficult to replace faulty elements and achieve desired illumination effects.
Innovation Solution
The LED projector design features a matrix of LEDs with interchangeable strips of lenses having asymmetric and symmetric sections, combined with a reflective sheet that can be angled and made of various materials, allowing for adjustable light beam shaping and directionality, and efficient heat management through ellipsoidal housings with unique heat channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple projectors are used to illuminate large areas, then the required illumination effect is achieved, but the cost and system complexity increase
Solution Approach 1:
The projector uses segmented lens strips that can be independently configured. Each strip contains multiple lenses that can be arranged in different patterns (symmetric or asymmetric) to control light distribution. This segmentation allows a single projector to achieve versatile illumination patterns that would otherwise require multiple projectors, reducing system complexity while maintaining illumination effectiveness.
Solution Approach 2:
The patent implements dynamic configurability through interchangeable lens strips with different optical characteristics. The system can adapt its light beam shape and intensity distribution by swapping lens strips, enabling a single projector to dynamically adjust to different illumination requirements for large areas without adding more projectors.
2Adaptability or versatility
If non-standardized projectors are used, then customization flexibility is achieved, but replacement of faulty elements becomes difficult
Solution Approach 1:
The projector is divided into modular components, particularly the lens strips, which are separate replaceable units. This segmentation allows individual lens strips to be replaced without affecting the entire projector system, making maintenance easier while still allowing customization through different strip configurations.
Solution Approach 2:
The patent employs universal mounting interfaces and standardized connection points for lens strips. Although the optical characteristics can be customized through different lens designs (symmetric or asymmetric), the mechanical interface remains standardized, enabling easy replacement and interchangeability of lens strips while maintaining customization flexibility.
3Adaptability or versatility
If complex lens arrangements are used to vary beam directionality and intensity distribution, then photometric curve flexibility is improved, but assembly complexity increases
Solution Approach 1:
The complex optical function is segmented into multiple lens strips, each with a specific optical profile. Instead of assembling a single complex lens system, the patent uses multiple simpler lens strips that can be independently manufactured and then combined to achieve the desired overall photometric curve, simplifying both manufacturing and assembly.
Solution Approach 2:
The patent combines multiple lens strips with different optical characteristics to achieve complex photometric curves. By merging the effects of several simpler lens strips (with symmetric or asymmetric designs), the system achieves the flexibility of complex optical arrangements while keeping individual components simpler and easier to assemble.
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 enables flexible and efficient illumination of large areas with reduced projector numbers, easy assembly and maintenance, and the ability to create a wide range of photometric curves, enhancing beam directionality and intensity distribution as desired.
Implementation Method 1
A sheet 4, which is vertical with respect to the support plane 11, is provided on each of said strips 2 of lenses 30... said sheet 4 provides a reflective surface 42 facing the front side of the projector 1 with LEDs 3
Implementation Method 2
Said lenses 30 act as diffusers and directors of the light of LEDs 3
Implementation Method 3
Said strips 2 of lenses 30 which are separably engageable on said motherboard 12... Strips 2 of lenses 30 parallel to one another identify a matrix 22 of lenses 30 on the motherboard 12
Implementation Method 4
Each of said housings 31 is provided with a heat outlet 5 comprising two channels of different length: the short channel 51 towards the front side of strip 2 and the long channel 52 towards the rear side of strip 2
Implementation Method 5
the short channel 51 and the long channel 52 have different lengths to advantageously promote the heat transmission and make ventilation even more effective
Data Source
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AI summary
A LEDs (3) projector (1) including a matrix (22) of lenses (30) comprising a plurality of housings (31) for LEDs (3) and a plurality of sheets (4), Each sheet extending upward with respect to the plane identified by the matrix of lenses. Each sheet (4) comprisng at least one reflective surface (42).