Multi-Layer Foil Lighting Unit for Thin Beam Shaping
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Solution Overview
Problem
Traditional beam shaping optical elements in lighting applications are either bulky or difficult and expensive to design and manufacture, limiting the flexibility and thinness of lighting units.
Innovation Solution
A lighting unit comprising a plurality of light source units and a multi-layer foil system with transmissive regions, where each region includes optical elements with refractive and total internal reflection functionalities, allowing for precise control of beam shape and direction, enabling narrow or broad beam production and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If classical beam shaping optical elements (reflectors and collimators) are used, then beam shaping capability is provided, but the construction becomes bulky
Solution Approach 1:
The patent uses thin foil structures with integrated micro-optical elements instead of bulky classical optics. The foils are positioned close to the LED chips (first foil at distance d1, second foil at distance d2 from LED array), providing beam shaping functionality in a compact form factor with total thickness significantly reduced compared to traditional reflector or collimator systems.
2Ease of operation
If custom beam shaping optics are designed, then precise beam control is achieved, but design and manufacturing complexity increases
Solution Approach 1:
The beam shaping function is segmented into two separate foils, each with specific optical elements. The first foil contains optical elements for initial light redirection, while the second foil contains optical elements for final beam shaping. This segmentation allows each foil to be optimized independently and manufactured separately, reducing overall design and manufacturing complexity while maintaining precise beam control capability.
Solution Approach 2:
The foils serve multiple functions: they provide mechanical support for the LED array, act as optical elements for beam shaping, and enable precise angular control of light output. By integrating these functions into thin foil structures rather than separate components, the patent reduces manufacturing steps and assembly complexity while achieving precise beam control.
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 provides a versatile lighting unit capable of producing beams with a full width half maximum (FWHM) of less than 20°, offering flexible beam shaping and direction control while maintaining a thin construction, enhancing optical efficiency and reducing glare.
Implementation Method 1
an optical element with refractive functionality to the light source unit light in a center of each region
Implementation Method 2
an optical element with total internal reflection functionality to the light source unit light in a peripheral area remote from said center in each region
Implementation Method 3
at its center an optical element with refractive functionality to the light source unit light
Implementation Method 4
in a peripheral area remote from its center an optical element with total internal reflection functionality to the light source unit light
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c~2f
AI summary
The invention provides a lighting unit (10) comprising (i) an arrangement (111) of a plurality of light source units (100) configured to provide corresponding light source unit light (101), (ii) a first foil (210) comprising a plurality of transmissive first foil regions (211), wherein each first foil region (211) comprises a plurality of optical elements (212), and (iii) a second foil (220) comprising a plurality of transmissive second foil regions (220), wherein each second foil region (221) comprises a plurality of optical elements (222), wherein each light source unit (100) has a corresponding first foil region (211) configured downstream of said light source unit (100) and a corresponding second foil region (221) configured downstream of said first foil region (211).