Trapezoidal LED Optical Element for Asymmetrical Wallwash
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Solution Overview
Problem
Existing wallwashers with LED light sources face challenges in achieving reproducible and compact asymmetrical light distribution due to large optical systems and complex manufacturing tolerances, which result in inconsistent illumination.
Innovation Solution
An elongate optical element with a trapezoidal cross-section featuring a curved light entry area, a lens-like free-form optics-covered light emission surface, and convexly curved side surfaces described by third-order or higher-order polynomials, combined with matrix-like free-form optics on the exit surface, allows precise control of light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If mechanically formed trough reflectors are used to achieve asymmetrical light distribution, then the desired two-dimensional light distribution on the wall is achieved, but the optical system becomes relatively large and manufacturing tolerances negatively affect reproducibility
Solution Approach 1:
The patent combines the light-guiding function and the light-shaping function into a single integrated optical element. The optical element has a light entry area that receives light from the LED circuit board and a light emission surface that emits the shaped light, merging what were previously separate components (reflector and light guide) into one compact unit. This reduces the overall optical system size while maintaining the asymmetrical light distribution capability.
Solution Approach 2:
The optical element employs curved surfaces including a curved bottom surface in the light entry area and a curved light emission surface with free-form optics. These curved geometries are specifically designed to control light propagation paths and achieve the desired asymmetrical light distribution pattern on the wall, replacing the mechanically formed trough reflector approach.
2Illumination intensity
If mechanically formed trough reflectors are used to achieve asymmetrical light distribution, then the desired two-dimensional light distribution on the wall is achieved, but manufacturing tolerances have a negative effect on reproducibility
Solution Approach 1:
The optical element employs curved surfaces including a curved bottom surface in the light entry area and a curved light emission surface with free-form optics. These curved geometries are specifically designed to control light propagation paths and achieve the desired asymmetrical light distribution pattern on the wall, replacing the mechanically formed trough reflector approach.
Solution Approach 2:
The patent specifies that the curved surfaces follow curves describable by third-order or higher-order polynomials. This mathematical characterization of the surface geometry allows for precise control of light distribution characteristics while providing a clear manufacturing specification that reduces tolerance variability and improves reproducibility across production batches.
3Illumination intensity
If linear LED circuit boards with trough reflectors are used, then area lighting for wall illumination is achieved, but the optical system requires relatively large dimensions
Solution Approach 1:
The patent combines the light-guiding function and the light-shaping function into a single integrated optical element. The optical element has a light entry area that receives light from the LED circuit board and a light emission surface that emits the shaped light, merging what were previously separate components (reflector and light guide) into one compact unit. This reduces the overall optical system size while maintaining the asymmetrical light distribution capability.
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 design enables efficient and reproducible asymmetrical light distribution with a compact optical system, ensuring uniform illumination of vertical surfaces while minimizing production tolerances and overall size, resulting in high-quality surface lighting.
Implementation Method 1
the bottom surface, the basic shape of the light-emitting surface and the two side surfaces are each convexly curved, with the bottom surface, the basic shape of the light-emitting surface and the two side surfaces each following curves that can be described by third-order or higher-order polynomials
Implementation Method 2
a light emission surface opposite the light entry area, which has a curved basic shape overlaid with lens-like free-form optics
Data Source
Figure 1~2
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AI summary
An optical element (10) for influencing the light emission of an elongated light source, in particular one or more elongated LED boards (50), extends in a longitudinal direction and has an approximately trapezoidal cross-section with a light entry area (11) facing the light source, which has a recess (12) with a curved bottom surface (13), a light emission surface (15) opposite the light entry area (11), which has a curved basic shape (16) to which lens-like freeform optics (17) are superimposed, and two curved side surfaces (21, 22) extending from the light entry area (11) to the light emission surface (15).