Shelf Light Lens with Segmented Projections for Targeted Illumination
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Solution Overview
Problem
Existing shelf lights have large lenses, complex manufacturing processes, and high costs, leading to inefficient light distribution with excessive light irradiation in aisles rather than on shelves, resulting in low light efficiency and increased energy consumption.
Innovation Solution
A lens design with a light receiving surface and a light distribution surface, featuring projections and a recessed portion, which refract and reflect light to target the shelves, achieving balanced light distribution and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large lens is used in existing shelf lights, then the light source can cover a wider area, but the light distribution becomes unbalanced with excessive light irradiation in aisles rather than on shelves, resulting in low light efficiency
Solution Approach 1:
The lens is segmented into multiple functional regions: a central recessed portion for downward light transmission and peripheral projections with reflective surfaces for lateral light reflection. This segmentation allows different parts of the lens to direct light to different locations (shelves vs. aisles), achieving balanced light distribution and improving light efficiency by preventing excessive light irradiation in aisles while maintaining wide coverage area.
2Area of stationary object
If a large lens is used in existing shelf lights, then the light source can cover a wider area, but the manufacturing process becomes more complex and cost increases
Solution Approach 1:
The lens is divided into a central recessed portion and peripheral projections that can be formed through a single injection molding process. This segmentation is achieved by designing the mold cavity with corresponding features, allowing the complex multi-region lens structure to be manufactured in one step without requiring multiple assembly operations, thus maintaining manufacturing simplicity despite the increased functional complexity.
Solution Approach 2:
The lens design utilizes parameter optimization in the injection molding process, including controlling the radius of curvature of the reflective surfaces, the height and diameter ratios of projections, and the depth of the central recess. By optimizing these geometric parameters, the lens achieves the desired light distribution pattern while being manufacturable through standard injection molding techniques without requiring complex multi-step processes.
3Manufacturing precision
If the lens shapes the light source, then light can be directed to shelves, but a large amount of light is still irradiated in the aisle between shelves, making light distribution unbalanced
Solution Approach 1:
Different regions of the lens are assigned different optical functions: the central recessed portion has a smooth inner wall that directly transmits light downward to shelves, while the peripheral projections have reflective surfaces angled to reflect light laterally. This local differentiation of optical properties ensures that each region contributes to its intended function, achieving balanced light distribution between shelves and aisles while maintaining precise light direction control.
Solution Approach 2:
The lens design employs asymmetric geometry with a central recessed portion and peripheral projections that break the rotational symmetry of a conventional lens. The projections are positioned at specific angles and heights to create asymmetric light reflection patterns that direct light preferentially toward shelves rather than aisles. This asymmetric design enables precise control over light distribution balance while maintaining the ability to shape and direct the light source effectively.
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 lens design enhances light distribution to shelves, reducing energy consumption and improving light efficiency by directing light effectively onto the merchandise, creating a more appealing shopping environment.
Implementation Method 1
said first incident surface is adapted to refract light to the first reflective surface
Implementation Method 2
said first reflective surface is adapted to reflect light to the light distribution surface
Implementation Method 3
refracted by the light distribution surface to the shelf
Implementation Method 4
said second incident surface, adapted to refract light to the light distribution surface and refracted by the light distribution surface to the shelf
Data Source
AI summary
A lens and light source module include: a light receiving surface; a light distribution surface, along the optical axis direction set opposite to the light receiving surface; light receiving surface away from the optical axis center region to form N groups of projection, where N≥1; each with a first incident surface and a first reflective surface. The first incident surface is adapted to refracting light to the first reflective surface; the first reflective surface is adapted to reflecting light to a light distribution surface and refracting light to a display by the light distribution surface. The lens provided by the present invention enables the majority of light to be directed to the shelf in a targeted manner, which is conducive to achieving balanced light distribution and enhancing light efficiency.