Compact Lighting Unit with Integrated Beam Shaping Reflectors
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Solution Overview
Problem
Slim downlights face challenges in achieving desired light quality due to the need for beam shaping, which often results in a large optic size relative to the light source, leading to increased height or reduced diameter, and complications such as high LED failure rates, electrical balancing issues, and high costs.
Innovation Solution
A lighting unit with a light mixing chamber featuring a ring of LEDs and a high reflective diffuse layer, where the rim is made by an LED board with chamber openings for light escape, allowing for beam shaping optics and secondary sources to be integrated in the same component, enabling a compact design with pseudo-random patterns for beam shaping and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If beam shaping optics are used to change light direction, then light distribution quality is improved, but the optic size becomes very large relative to the source, increasing the required height of the lighting unit
Solution Approach 1:
The invention divides the single large light source into multiple small light sources arranged in a specific pattern. Each small source has a corresponding small optic element, allowing the system to achieve the desired light distribution without requiring a single large optic that would increase the overall height of the lighting unit.
Solution Approach 2:
The invention transitions from a single large source-optic configuration to a multi-source multi-optic arrangement distributed in a planar pattern. This dimensional redistribution allows the beam shaping function to be achieved across a wider area rather than requiring vertical stacking, thus reducing the height while maintaining light distribution quality.
2Length of stationary object
If multiple small light sources are used to reduce optic size, then the required height is reduced, but alignment of sources to optics becomes difficult including thermal expansion effects
Solution Approach 1:
The invention integrates the light sources and optic elements into a unified structure where the sources are positioned in direct contact with or immediately adjacent to their corresponding optics. This merging approach ensures that thermal expansion affects both components equally, maintaining their relative alignment without requiring precise pre-alignment that would be necessary if they were separate assemblies.
Solution Approach 2:
Each light source is locally coupled to its corresponding optic element with a dedicated interface designed to maintain alignment. This local coupling ensures that even with thermal expansion, the source-optic pairs remain properly aligned because they expand together as a localized unit rather than requiring global alignment across the entire array.
3Shape
If many individual LEDs are used to create small sources, then small source size is achieved, but LED failure risk increases and electrical systems become complex
Solution Approach 1:
The invention uses a single light source that performs multiple functions: it provides the necessary light output while its edge acts as the effective small source for the optic coupling. This eliminates the need for multiple individual LEDs, thereby reducing failure risk while maintaining the small effective source size required for compact optic design.
Solution Approach 2:
Instead of using multiple physical LEDs, the invention creates an effective multi-source pattern through the edge geometry of a single source. The edge of the light source creates multiple emission points that function similarly to multiple individual LEDs, achieving the desired small source characteristics without the reliability penalties of using actually multiple LED components.
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 solution allows for a low-profile lighting unit with effective passive and active cooling, improved light distribution, and reduced glare, while maintaining high luminance intensity and ease of production, suitable for various applications including indoor and outdoor spaces.
Implementation Method 1
top and bottom side(s) may be closed by a high reflective diffuse layer
Implementation Method 2
the beam shaping elements especially comprise reflectors
Data Source
Figure 1A~1C
Figure 2A~2B(III)
Figure 2C~2D
AI summary
The invention provides a lighting unit (1000) comprising a light mixing chamber (100) defined by faces (110) and an edge face (130), wherein a height (H) of the light mixing chamber (100) defined by a distance between the faces (110) is smaller than a first length (L1) of the light mixing chamber (100), wherein the lighting unit comprises a plurality of light sources (10) configured to provide light source light (11) in the light mixing chamber (100), wherein at least one of the faces (110) comprises a plurality of chamber openings (141) for escape of at least part of the light source light (11) from the light mixing chamber (100), wherein the lighting unit (1000) further comprises a plurality of beam shaping elements (150), with each beam shaping element (150) configured downstream from a corresponding chamber opening (141), and wherein the beam shaping elements (150) comprise reflectors (200).