Light Engine Assembly Using Reflector-LED Pairing for Beam Uniformity
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Solution Overview
Problem
Existing light engine assembly methods fail to efficiently achieve a consistent light output profile with varying numbers of light emitting diodes, as different boards produce different luminous fluxes and beam angles, making it difficult to achieve uniform light distribution across different luminaires.
Innovation Solution
A method and system for assembling a light engine that involves selecting a reflector based on a desired light output profile and pairing it with light boards having different numbers of LEDs, ensuring each board produces a consistent beam shape and angle when coupled with the reflector, regardless of the number of LEDs, by maintaining a consistent average LED distance to the center and source extent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different light boards with varying numbers of LEDs are used, then brightness and energy consumption options increase, but light output consistency and beam uniformity deteriorate
Solution Approach 1:
The patent applies parameter changes by systematically varying the number of LEDs on different light boards while maintaining consistent optical parameters through the reflector design. Each light board configuration (different LED counts) is paired with a specific reflector that compensates for the varying luminous flux, transforming the parameter of LED quantity into a controlled variable that does not compromise beam uniformity. This allows the system to offer multiple brightness levels while maintaining consistent beam angles and light distribution patterns.
Solution Approach 2:
The reflector is designed as a universal component that can be paired with multiple different light board configurations. A single reflector design can accommodate light boards with varying numbers of LEDs, making the optical system multi-functional. This universality allows the same reflector to work across different brightness configurations, ensuring consistent beam output regardless of which light board is installed, thereby resolving the contradiction between versatility and consistency.
2Illumination intensity
If more LEDs are added to increase luminous flux, then brightness increases, but beam angle control and light distribution uniformity become more difficult
Solution Approach 1:
The patent changes the parameter of luminous flux by adding or removing LEDs while maintaining beam angle consistency through corresponding reflector adjustments. Each increment in LED quantity is paired with a reflector design parameter adjustment that preserves the beam angle, transforming the potential problem of beam distortion into a controlled parameter relationship between LED count and reflector geometry.
Solution Approach 2:
The reflector design applies local quality by adjusting specific geometric parameters of the reflector surface to compensate for the distributed light sources. Rather than treating all LEDs uniformly, the reflector is customized with specific local surface properties and angles that account for the particular LED arrangement and quantity, ensuring that each light board configuration produces the desired beam angle and uniformity.
3Adaptability or versatility
If light boards with different LED configurations are used, then customization options increase, but achieving uniform light distribution across all configurations becomes more complex
Solution Approach 1:
The patent achieves universality by designing a standardized reflector interface and mounting system that accommodates multiple light board configurations. The reflector and housing are designed with universal features that allow different LED configurations to be installed using the same assembly procedures, reducing complexity despite increased configurability. This universal design approach allows the system to offer customization while maintaining simple, consistent assembly processes.
Solution Approach 2:
The system is segmented into modular components: standardized light boards with varying LED configurations and standardized reflectors with specific optical parameters. This segmentation allows independent optimization of each component while maintaining compatibility across the system. The modular approach simplifies assembly by allowing pre-configured light boards to be paired with appropriate reflectors through standardized interfaces, reducing overall system complexity.
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 approach allows for flexible and customizable light engine assembly, enabling consistent light output profiles across various luminaires with different LED configurations, allowing users to select boards based on brightness, energy consumption, and cost while maintaining a uniform beam shape and angle.
Implementation Method 1
selecting a reflector based on the desired light output profile... positioning the one of the first light board and the second light board within the housing, adjacent the reflector
Data Source
AI summary
A system and method of assembling a light engine includes determining a desired light output profile for the light engine, selecting a reflector based on the desired light output profile, and selecting one of a first light board and a second light board. The first light board includes a different number of light emitting diodes than the second light board. Each of the first light board and the second light board are capable of providing the desired output light profile when they are coupled with the selected reflector. The method also includes positioning the one of the first light board and the second light board within the housing, adjacent the reflector.