Aircraft Light Silicone Optics Assembly for Complex Geometry Positioning
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Solution Overview
Problem
Existing aircraft lights face challenges in manufacturing and assembly due to complex optical element geometries, requiring reliable positioning and efficient attachment to support elements.
Innovation Solution
The use of an injection molded optical element made of light transmissive silicone rubber, adhered to a support element via a layer of light transmissive silicone rubber, allowing for complex geometries to be formed efficiently and securely attached using lower pressures, with optional kinematic coupling fixtures for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If injection molding is used to form complex optical elements, then manufacturing efficiency and geometric complexity are improved, but the risk of component damage during molding increases
Solution Approach 1:
The optical element is divided into two distinct parts: an injection molded portion formed at high pressure for complex geometry, and a gravity molded portion formed at low pressure for adhesion. This segmentation allows each part to be optimized for its specific function, resolving the contradiction between manufacturing efficiency and damage risk.
Solution Approach 2:
The molding process uses two different pressure parameters: high pressure for injection molding the complex geometry portion, and low pressure (gravity molding) for forming the adhesion layer. This parameter change enables efficient manufacturing of complex shapes while preventing damage during the bonding process.
2Adaptability or versatility
If complex geometries are implemented in optical elements, then light output functionality is improved, but manufacturing complexity increases
Solution Approach 1:
The optical element is segmented into an injection molded portion that handles complex geometry requirements for light output, and a separate gravity molded portion for adhesion. This allows complex functionalities to be achieved without proportionally increasing overall manufacturing complexity.
Solution Approach 2:
Two different molding processes (injection molding and gravity molding) are merged into a single integrated component. The injection molded portion provides complex geometry for optical functionality, while the gravity molded portion provides adhesion, combining both requirements in one piece.
3Manufacturing precision
If high pressure is used in molding, then geometric precision is improved, but the risk of damaging support elements increases
Solution Approach 1:
The molding process is segmented into two stages: high pressure injection molding for the optical portion requiring geometric precision, and low pressure gravity molding for the adhesion layer. This segmentation allows high precision where needed without exposing the support element to damaging pressures.
Solution Approach 2:
Different pressure conditions are applied to different portions of the molding process: high pressure locally for the optical element geometry, and low pressure for the adhesion layer. This local quality approach ensures geometric precision where required while protecting the support element from damage.
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
Facilitates easy and reliable assembly of aircraft lights with complex geometries, reducing the risk of damage during manufacturing and ensuring accurate light output, while providing protection and stability.
Implementation Method 1
A layer of light transmissive silicone rubber is arranged between at least a portion of the injection molded optical element and at least a portion of the support element. The layer of light transmissive silicone rubber provides adhesion between the injection molded optical element and the support element.
Implementation Method 2
manufacturing an injection molded optical element from liquid light transmissive silicone rubber by injection molding
Implementation Method 3
The layer of light transmissive silicone rubber may in particular be formed by introducing a fluid phase of the light transmissive silicone rubber between the support element and the injection molded optical element only driven by gravity.
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An aircraft light (2) comprises: a support element (4), supporting at least one light source (6); an injection molded optical element (8), made of light transmissive silicone rubber; and a layer of light transmissive silicone rubber (12) arranged between at least a portion of the injection molded optical element (8) and at least a portion (4b) of the support element (4). The layer of light transmissive silicone rubber (12) provides adhesion between the injection molded optical element (8) and the support element (4).