Lighting Module With Microporous Back Plate for Acoustic and Optical Performance

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Solution Overview

Problem

Large area lighting modules face challenges in providing both effective acoustic dampening and optimal optical performance, with existing solutions being either cost-prohibitive or compromising on acoustic or optical efficiency.

Innovation Solution

A lighting module design featuring a back plate with micrometer-sized holes for sound attenuation and a light mixing chamber with a transmissive cover plate and reflective surfaces to minimize light losses, allowing for both efficient sound absorption and homogeneous luminous output.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If glass fibre-based carrier plates are used for acoustic dampening, then acoustic performance is improved, but optical reflectivity is limited to 80-85% which is suboptimal

Engineering Contradiction:
Improveacoustic performanceVSAvoidoptical reflectivity
Core Design Contradiction:
Object-affected harmful factorsVSIllumination intensity

Solution Approach 1:

The patent employs a composite structure combining a glass fibre-based carrier plate for acoustic dampening with a white pigment layer (such as titanium dioxide) applied to its surface. This composite approach allows the glass fibre plate to provide excellent acoustic absorption while the white pigment layer enhances optical reflectivity to achieve homogeneous light distribution, thereby resolving the contradiction between acoustic performance and optical efficiency.

Inventive Principle:
Principle #40Composite materials

2Illumination intensity

If advanced coatings such as sol-gel coatings are applied to improve optical reflectivity, then optical efficiency is improved, but manufacturing cost becomes prohibitive

Engineering Contradiction:
Improveoptical reflectivityVSAvoidmanufacturing cost
Core Design Contradiction:
Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive advanced coatings like sol-gel with a cost-effective white pigment layer (such as titanium dioxide) that can be applied using conventional, simple coating techniques. This substitution maintains high optical reflectivity and homogeneous light distribution while significantly reducing manufacturing costs, making the solution economically viable for large area lighting applications.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Illumination intensity

If large area panels are manufactured as single units, then optical homogeneity is achieved, but they become cumbersome to manufacture and handle

Engineering Contradiction:
Improveoptical homogeneityVSAvoidmanufacturability
Core Design Contradiction:
Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent divides large area lighting panels into multiple smaller modular units, each containing LED modules mounted on glass fibre-based carrier plates. These modules can be manufactured separately using conventional techniques and then assembled into larger panel configurations. This segmentation maintains optical homogeneity through proper module arrangement while dramatically improving ease of manufacture, handling, and installation.

Inventive Principle:
Principle #1Segmentation

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 effectively combines excellent acoustic performance with high optical efficiency, reducing glare and improving the aesthetic appearance of large area lighting panels while simplifying their assembly and manufacturing.

Implementation Method 1

the back plate comprises a plurality of through holes, each through hole having a diameter in a range of 50 to 500 micrometers

Methodology Applied
Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 2

a light mixing chamber delimited by a back plate opposed by a cover plate and a sidewall arrangement extending between the back plate and the cover plate

Methodology Applied
Scientific EffectLight reflection: Reflection

Data Source

PatentUS11320139B2Lighting module, kit and panel
Publication Date: 2022.05.03 SIGNIFY HOLDING BV
  • US11320139B2 patent drawing
  • US11320139B2 patent drawing
  • US11320139B2 patent drawing

AI summary

A lighting module (10) is disclosed comprising a light mixing chamber (35) delimited by a back plate (40) opposed by a cover plate (20) and a sidewall arrangement (30) extending between the back plate (40) and the cover plate (20); and a light source (45) mounted on the back plate (40) and arranged to emit light into the light mixing chamber (35), wherein the cover plate (20) is transmissive for light emitted by the light source (45) and transmissive for sound waves, and wherein the back plate (40) comprises a plurality of through holes (41), each through hole (41) having a diameter in a range of 50 to 500 micrometers. Also disclosed are a lighting kit comprising a plurality of such lighting modules (10) and a lighting panel assembled from such a lighting kit.