Thin Luminaire With Variable Aperture Optics
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Solution Overview
Problem
Existing light-emitting diode (LED) luminaires have limitations in producing uniform and adjustable light emission patterns, as they require a uniform distribution of holes and optics, resulting in fixed emission patterns and a planar device shape, which is not suitable for applications like car headlamps that need complex and curved designs.
Innovation Solution
The design introduces variable shapes and positions for holes and refractive optical elements, allowing for customizable beam patterns and device shapes, including curved surfaces, using a reflective mixing box with LEDs mounted on its surfaces and refractive optics that can be offset, enabling the production of complex emission patterns and adjustable light outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a uniform distribution of holes and optics is used, then uniform light emission is achieved, but the emission pattern becomes fixed and the device shape is limited to planar
Solution Approach 1:
The patent applies local quality by allowing different holes and corresponding optics to have varying shapes and relative positions across the device. This enables each local region to contribute differently to the overall emission pattern, achieving both uniformity through careful design and versatility through local variation. The holes can take on any shape required and do not have to be the same shape, allowing infinite patterns to be generated.
Solution Approach 2:
The patent introduces dynamics by allowing moving parts relative to each other or replacing a limited number of parts in the system. This enables the same device to produce different emission patterns dynamically, transforming from a static uniform emitter to a dynamically adjustable system that can adapt to various application requirements.
2Shape
If all holes and corresponding optics are coplanar, then a planar device is achieved, but the device cannot conform to curved surfaces like car headlamps
Solution Approach 1:
The patent applies spheroidality by allowing the overall shape of the device to be curved rather than strictly planar. This enables the device to conform to curved surfaces such as car headlamp housings while maintaining its optical functionality. The curved geometry allows the luminaire to integrate seamlessly into applications requiring non-planar mounting surfaces.
3Illumination intensity
If the array of optics is tailored to produce collimation, then beam directionality is improved, but the emission patterns that can be produced are limited
Solution Approach 1:
The patent resolves this contradiction by allowing each optic to have varying shapes and positions, enabling some optics to produce collimated beams while others produce different patterns. This local variation allows the system to simultaneously achieve beam directionality where needed and pattern diversity across different regions of the device.
Solution Approach 2:
The patent applies universality by designing a system where the same basic optical components can serve multiple functions. By varying the shapes and relative positions of holes and optics, the system can produce multiple emission patterns including collimated beams, wide-angle distributions, and asymmetric patterns, making the device universally applicable to various lighting requirements.
4Ease of manufacture
If the device is designed to produce a fixed light emission, then manufacturing is simplified, but the emission pattern cannot be changed or adjusted
Solution Approach 1:
The patent introduces dynamics by incorporating moving parts or replaceable components that allow the emission pattern to be changed. This transforms a previously static, fixed-design device into one that can adapt its emission characteristics while maintaining relatively simple manufacturing processes for each configuration.
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 approach enables the creation of ultra-thin luminaires with high optical efficiency, capable of producing a wide range of beam patterns and colors, suitable for various applications such as automotive headlamps, downlights, and troffers, with improved beam control and color mixing, achieving over 80% optical efficiency and tunable light outputs.
Implementation Method 1
Embodiments of the luminaires described in this specification use a reflective mixing box (whose walls can be specular or diffusive or a combination of both)
Implementation Method 2
The light sources, which are preferably light emitting diodes (LEDs), are mounted on any of the surfaces of the mixing box... The mixing box can if desired sufficiently homogenize the light sources so that the output is substantially spectrally uniform
Implementation Method 3
Above each hole there is a refractive optical element that transforms the light emitted by the holes into the required beam pattern or patterns
Implementation Method 4
The light sources, which are preferably light emitting diodes (LEDs)... In either case the mixing box can if desired sufficiently homogenize the light sources
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
A luminaire includes a mixing chamber having an array of apertures in one wall, a light source to supply light into the mixing chamber, and an array of optics outside the mixing chamber, each positioned to cooperate with a respective one of the apertures to emit light from the mixing chamber as a beam. The shape, size, and/or direction of the output light beam are controllably varied by controlling the shape, size, and/or position of each aperture relative to its associated optic.