Adjustable Optical Module for Multi-Height LED Alignment
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Solution Overview
Problem
Existing LED assemblies require specific optical modules for each type of LED, leading to increased manufacturing costs and reduced flexibility, as different LEDs have varying heights due to substrate and light conversion layer thicknesses, necessitating changes in optical module positioning for optimal luminous output.
Innovation Solution
An optical module with a stepped arrangement of rotatable mounting structures, allowing for multiple mounting heights and automatic alignment with a carrier's apertures, enabling the use of the same optical module with various LED heights without the need for specific optical modules, thus reducing manufacturing costs and enhancing design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed-height optical module is used for a specific LED type, then optimal optical alignment is achieved for that LED type, but the assembly cannot accommodate different LED heights without replacing the optical module
Solution Approach 1:
The mounting structure is made adjustable through a mechanism that allows the optical module to be positioned at different heights. The mounting post includes a threaded rod that can be rotated to change the height of the optical module relative to the carrier, enabling adaptation to different LED heights while maintaining optimal optical alignment.
Solution Approach 2:
The height parameter of the optical module mounting position is made variable. By changing the mounting height through the adjustable mechanism (rotating the threaded rod to move the mounting block along the post), the same optical module can accommodate different LED types with varying heights, resolving the contradiction between adaptability and device complexity.
2Reliability
If different optical modules are manufactured for each LED type to ensure correct mounting height, then optimal luminous output is achieved, but manufacturing costs increase
Solution Approach 1:
A single optical module design with an adjustable mounting structure serves multiple functions by accommodating different LED types. The universal mounting post and mounting block mechanism allow the same optical module to be used with various LED heights, eliminating the need to manufacture separate optical modules for each LED type while maintaining optimal luminous output.
Solution Approach 2:
The adjustable mounting mechanism enables one optical module design to adapt to multiple LED types dynamically. By allowing height adjustment through the threaded rod and mounting block system, the same optical module can achieve optimal positioning for different LEDs, reducing manufacturing costs while maintaining reliability.
3Productivity
If the optical module mounting height is fixed during manufacture, then production is simplified, but flexibility to choose LEDs later is lost
Solution Approach 1:
The mounting structure incorporates a dynamic adjustment mechanism that allows height to be changed after the optical module is manufactured. The threaded rod and mounting block allow operators to adjust the optical module height to match different LED types during assembly, maintaining both production efficiency and design flexibility.
Solution Approach 2:
The optical module is manufactured with a pre-configurable mounting structure that includes the adjustable mechanism. This preliminary preparation of the mounting post and block allows for quick adjustment during assembly without requiring complex manufacturing processes, balancing productivity with adaptability.
Data Source
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AI summary
An optical module (30) for a LED assembly (1) is disclosed. The optical module comprises a plurality of optical elements (31) and a plurality of mounting structures (40), each mounting structure comprising a stepped arrangement of mounting elements, in which each mounting element defines a step of the stepped arrangement, each step defining a different mounting height for the optical module. Also disclosed are a LED assembly including such an optical module, a luminaire including such a LED assembly and a method of assembling such a LED assembly.