Mirror-Reflection Lens Slats with Variable Optics and Lower Tooling
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Solution Overview
Problem
Existing light deflection systems with bifocal optics face challenges in producing slim slats with numerous small teeth due to the need for large machines and high tool costs, and suffer from twisting and edge waviness, requiring separate forming tools for different sun angles and limiting design flexibility.
Innovation Solution
A slat body with variable optics is developed, allowing for separate production of reflector strips with different manufacturing processes, which can be combined in a parallel arrangement to create variable light control systems without the need for special tools, using materials like aluminum or plastic for the slat body and metallized foils for reflectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If roll forming process is used to produce slats with many small teeth in retro-reflective section, then transparency and diffuse light penetration are improved, but manufacturing complexity and tool costs increase significantly
Solution Approach 1:
The slat is divided into two separate components: a slat body and a reflector strip. The reflector strip contains the tooth-shaped contour for retro-reflection, while the slat body provides structural support. This segmentation allows the reflector strip to be produced using simpler methods (printing, metallizing) rather than complex roll forming, thereby reducing tool costs while maintaining the desired optical properties.
Solution Approach 2:
The tooth-shaped contour is transferred from a three-dimensional roll forming tool to a two-dimensional printed pattern on the reflector strip. This dimensional change enables the production of complex tooth patterns without requiring equally complex forming tools, significantly reducing manufacturing complexity while achieving the same optical effect.
2Reliability
If roll forming process is used to produce slats with many small teeth, then retro-reflective function is achieved, but production time and machine size requirements increase
Solution Approach 1:
The manufacturing process is segmented into separate steps: producing the slat body, producing the reflector strip independently, and assembling them. This allows parallel production of components and eliminates the need for large, slow roll forming machines, thereby increasing overall production speed while maintaining retro-reflective functionality.
Solution Approach 2:
The mechanical roll forming process is replaced with a combination of printing, metallizing, and assembly processes. These alternative methods are faster and require smaller equipment, thereby improving productivity while achieving the same retro-reflective function through the tooth-shaped contour.
3Stability of the object's composition
If fixed connections of retro-reflector and light deflection section are used, then structural stability is achieved, but adaptability to different latitudes and configurations is reduced
Solution Approach 1:
The connection between the slat body and reflector strip is made detachable rather than fixed. This allows the reflector strip to be removed and replaced with different types depending on the required optical function (retro-reflection, light deflection, or combination). The slat body remains structurally stable while the optical components can be dynamically changed to adapt to different latitudes and configurations.
Solution Approach 2:
The slat body is designed as a universal platform that can accommodate multiple types of reflector strips with different optical functions. By keeping the connection detachable, a single slat body design can serve multiple purposes across different latitudes and applications, significantly improving versatility without compromising structural stability.
4Manufacturing precision
If separate forming tools are used for different reflector configurations, then optical precision is maintained, but tooling costs and inventory requirements increase
Solution Approach 1:
Instead of using expensive custom-forming tools for each reflector configuration, the tooth-shaped contour is created by printing a precise pattern onto the reflector strip and then metallizing it. This copying approach maintains optical precision through accurate printing while eliminating the need for expensive custom tooling, significantly reducing tooling costs and inventory requirements.
Solution Approach 2:
The optical properties of the reflector strip are changed by varying the printed pattern parameters (tooth size, spacing, shape) rather than changing the physical forming tools. This allows multiple optical configurations to be produced using the same printing and metallizing equipment, thereby maintaining manufacturing precision while reducing tooling costs and simplifying production.
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
Enables production of slim slats with variable optics, allowing for different lighting scenarios and sun protection without constant tool investment, while maintaining uniform design and static stability, and supporting integration of LED strips and photovoltaics.
Implementation Method 1
a first stepped section of the slats (hereinafter referred to as retro-reflector) deflects the solar radiation impinging on it back into the sky as a result of a tooth-shaped contour
Implementation Method 2
a second, flatter section (hereinafter referred to as light deflecting section), which directs the incident radiation inwards
Data Source
AI summary
The invention relates to a light deflection system with mirror reflection optics for deflecting light radiation. The slat system consists of a statically load-bearing slat body, wherein the slat body 10, 63, 40, 105 accommodates at least two individual reflector strips on its upper side 31, 32, 33, 34, 52, 53, 64, 65, 103 to 105). At least one reflector strip 31, 33, 64 has at least one toothed, light-reflecting upper side and at least one reflector strip 32, 34, 64 has a smooth and/or stepped, light-reflecting upper side, which is characterised by the reflector strip 31, 33, 64 with a serrated contour can deflect light in the direction of the incidence of light A and the reflector strip 32, 34, 65 with a smooth and/or stepped contour can deflect light into a half-space I opposite the incidence of light. When the reflector strips are arranged in parallel, a bifocal optical system is created with a focus on the side of light incidence A and a focus on an opposite side I of the lens body.