Clover Leaf Reflector Body for Light-Curing Devices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light-curing devices face challenges in achieving flexibility and cost-effectiveness while maintaining constant optical quality, particularly in the assembly and manufacturing of reflector bodies with multiple LED chips, which require complex and costly processes.
Innovation Solution
The use of a reinforcing ring or wall surrounding the reflector body with closely adjacent reflection elements, which are optionally intersecting, helps maintain optical axis alignment and provides cooling, allowing for a single injection molded part and flexible configuration with sensors for enhanced cooling and reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple separate injection molded parts are used to create reflector bodies with expansion gaps, then thermal expansion accommodation is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges multiple separate reflector body parts into a single integrated injection molded component. The reinforcing wall structure provides the necessary thermal expansion accommodation while maintaining structural integrity, eliminating the need for multiple separate parts and complex assembly procedures.
Solution Approach 2:
The reinforcing wall serves multiple functions simultaneously: it provides structural reinforcement, accommodates thermal expansion through its design, and enables a single-mold manufacturing process. This multi-functionality reduces both device complexity and manufacturing steps.
2Manufacturing precision
If individual metal substrate bodies with machined reflectors are used, then manufacturing precision is improved, but ease of manufacture and flexibility deteriorate due to requiring multiple machine tools
Solution Approach 1:
The patent replaces mechanical machining processes with injection molding technology. The reinforcing wall structure is directly formed during molding, eliminating the need for separate machining operations on metal substrates while maintaining the required precision through mold-based geometry control.
Solution Approach 2:
The invention changes the manufacturing approach from subtractive machining to additive molding. By controlling the geometric parameters of the reinforcing wall during injection molding, the same precision can be achieved without requiring multiple machine tools, thereby improving ease of manufacture.
3Stability of the object's composition
If reflection elements are spaced apart with expansion gaps, then thermal expansion is accommodated, but optical quality deteriorates due to disrupted light reflection
Solution Approach 1:
The reinforcing wall is designed with an asymmetric profile that provides differential support to adjacent reflection elements. This asymmetric structure allows for controlled thermal expansion in specific directions while maintaining the optical alignment of reflection elements, preventing disruption of light reflection patterns.
Solution Approach 2:
The reinforcing wall structure is pre-designed to counteract thermal expansion effects before they can disrupt optical alignment. By providing predetermined geometric compensation in the mold design, the structure prevents reflection elements from shifting out of alignment during thermal cycles.
4Manufacturing precision
If closely adjacent reflection elements are used without reinforcing structures, then optical quality is improved, but structural stability deteriorates due to thermal deformation
Solution Approach 1:
The reinforcing wall structure is incorporated into the injection mold design before the actual manufacturing process. This preliminary inclusion ensures that structural reinforcement is built-in from the start, preventing thermal deformation of closely spaced reflection elements without requiring post-manufacturing modifications.
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 solution reduces manufacturing costs, enhances flexibility, and maintains constant optical quality by stabilizing the reflector body and allowing for various LED chip configurations, including high-power setups with different emission wavelengths, while minimizing deformation and thermal impact.
Implementation Method 1
The chips heat up upon emission of light, which is accompanied by emission of heat, subsequently also heating the reflector body
Implementation Method 2
The chips heat up upon emission of light, which is accompanied by emission of heat
Implementation Method 3
It is possible for each of the reflectors to symmetrically expand via an expansion gap between the individual reflection elements
Implementation Method 4
By the annular, especially circular reinforcing wall it is virtually avoided for the reflection elements to displace 'apart from each other' upon heating and the optical axes thereof to outwardly displace
Implementation Method 5
the sensor openings that are provided between the reinforcing wall and the clover leaf, in addition allow air to enter, thus contributing to further cooling the reinforcing wall
Data Source
AI summary
The invention relates to a light-curing device, comprising a plurality of individual LED chips, each associated to a reflector, which LED chips are in particular each separately controllable and are arranged about a common central axis, in particular in each case at the same distance, and comprising reflection elements of the reflectors which adjoin one another, wherein the distance of the reflectors from one another is in each case substantially less, in particular less than a fifth, of the reflectors' diameter. The reflection elements (14, 16, 18, 20) are arranged like a clover leaf and are part of a common reflector body (10) which separates the reflection elements (14-20) from one another by means of dividing walls (30, 32, 34, 36), and the reflector body (10) has externally on the reflection elements (14-20) reinforcing walls (40) which—in relation to each cone (14, 16, 18, 20)—lie opposite the central axis (12).