Modular Multi-Aperture Reflector Sheets for Luminaire Light Distribution
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Solution Overview
Problem
Luminaire manufacturers face complications and increased costs due to the need for multiple unique optical reflector and lens designs to achieve custom light distribution in various lighting applications, and existing optics often block or degrade UV light, which is problematic for applications like UV curing and horticulture.
Innovation Solution
The use of modular multi-aperture reflective sheets that can be easily installed and replaced on luminaires to adjust, enhance, or correct light distribution, allowing for UV transmission and reducing the need for complex lens designs, while being compatible with standard reflectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple unique optical reflector and lens designs are used to achieve custom light distribution, then light distribution performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single standardized reflector geometry that can serve multiple lighting applications. Instead of creating unique reflectors for each application, the same reflector design is used across different luminaires, and light distribution is customized through interchangeable lens assemblies or optical control components. This reduces device complexity while maintaining the ability to achieve custom light distribution patterns.
Solution Approach 2:
The patent segments the optical system into separate functional components: a standardized reflector and interchangeable lens assemblies or optical control components. This segmentation allows the reflector to remain simple and standardized while the lens assemblies provide the customization for different light distribution patterns. Each lens assembly can be independently designed and swapped without affecting the reflector design.
2Illumination intensity
If multiple unique optical reflector and lens designs are used to achieve custom light distribution, then light distribution performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by making the reflector a universal, standardized component that can be produced in large volumes for multiple applications. The interchangeable lens assemblies or optical control components are designed to work with this single reflector geometry, allowing manufacturers to produce the reflector once and reuse it across different luminaire models, thereby reducing per-unit manufacturing costs while still providing custom light distribution options.
Solution Approach 2:
The patent employs more inexpensive lens assemblies or optical control components that can be easily manufactured and replaced. These interchangeable components are designed to be cost-effective alternatives to custom-molded lenses, allowing for lower material and tooling costs. The standardized interface between the reflector and these components enables easy assembly and replacement without expensive tooling or complex manufacturing processes.
3Illumination intensity
If traditional glass or plastic lenses are used, then light distribution control is improved, but UV light transmission is blocked or degraded
Solution Approach 1:
The patent changes the material parameter of the optical components by using materials that are transparent to UV light, such as certain plastics or glass formulations specifically selected for UV transmission. This parameter change allows the optical control function to be maintained while enabling UV light to pass through the lenses or optical control components without significant absorption or degradation, thus resolving the contradiction between light distribution control and UV transmission.
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 simplifies luminaire design and manufacturing, reduces costs by allowing a single luminaire design to serve multiple applications with different light distributions, and enables effective UV light transmission, thereby enhancing performance and flexibility in lighting installations.
Implementation Method 1
Multi-aperture reflector sheets are highly reflective, thin planar sheets that are purposely patterned with multiple apertures to enhance, adjust, vary, or correct the light distribution of a luminaire
Implementation Method 2
They can also be described as a reflective member, with distributed emitting elements spatially disposed to allow the transmission of infrared, visible, and UV light
Data Source
AI summary
A system of modular multi-aperture reflector sheets for use in general and specialty luminaires is disclosed. These sheets, designed to be simple in design, manufacture, and installation, allows for enhancing, adjusting, varying, or correction of the light distribution provided by luminaires during production or deployment. The reflector sheets are made of highly-reflective, thin material and feature multiple apertures that are patterned to redirect the light output emerging from the output of a luminaire. The reflector sheets are intended to be used in combination with both standard and custom reflectors and replace complicated and expensive lenses and optics that are often deployed to modify luminaire light distribution. The sheets are modular and can be replaced easily, allowing for standard luminaires having multiple possible light distribution patterns without further complication. Also, custom multi-aperture reflector sheets can be designed, shipped, and installed easily if further modification or correction of the light distribution is desired.