Coextruded Luminaire Element for Reflector and Diffuser Integration
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Solution Overview
Problem
Existing lamp designs require significant design effort due to multiple parts and complex assembly processes for lighting elements, such as reflectors and diffuser discs, which increases manufacturing complexity and costs.
Innovation Solution
A one-piece coextruded lighting element with functionally and materially distinct areas, such as a reflector and diffuser disc, made from materials like PMMA or PC, that can be easily fastened into a lamp housing using a simple snap-fit mechanism, reducing the number of parts and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate lighting elements (reflector, diffuser disc) are used with individual holders and connecting elements, then each element can be optimized for its specific function, but the device complexity and manufacturing effort increase significantly
Solution Approach 1:
The patent combines the reflector and diffuser disc into a single integrated lighting element made from coextruded profile. This merging eliminates the need for separate holders and connecting elements for each component, reducing assembly complexity while maintaining the distinct optical functions of both areas through their different material properties and geometric configurations.
Solution Approach 2:
The single lighting element performs multiple functions simultaneously: the first area acts as a reflector to direct light, while the second area serves as a diffuser to scatter light. The coextruded profile structure provides both structural support and optical functionality, eliminating the need for separate structural components for each functional area.
2Ease of manufacture
If multiple separate lighting elements with individual holders are used, then each element can be independently manufactured, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The reflector and diffuser disc are manufactured as a single coextruded profile, which reduces the number of assembly steps required. Instead of separately mounting each element with individual holders and connecting elements, the integrated design allows for simpler installation as a single unit, significantly reducing assembly time and increasing productivity.
3Strength
If traditional separate elements with holders and connecting elements are used, then structural support is provided, but additional fastening components increase manufacturing costs
Solution Approach 1:
The structural support function is integrated directly into the coextruded profile structure itself, eliminating the need for separate holders and fastening components. The profile's geometric design provides the necessary mechanical strength and mounting capability while reducing the total number of parts and associated manufacturing costs.
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 simplifies the fastening process, reduces manufacturing effort, and enhances light reflection and diffusion efficiency without additional costs, allowing for easier replacement of light sources and improved optical performance.
Implementation Method 1
A reflector, which is intended to direct the light emitted by the lamp in the desired direction
Implementation Method 2
A diffuser disc consists of a transparent or semi-transparent material... the base area by a second area, such as a diffuser area. In this case, the light from the illuminant is reflected on the side walls and the base area is diffusely illuminated.
Data Source
Figure 1
AI summary
A luminaire has a luminaire element (8), an elongate or rod-shaped light-emitting means (7) and a housing (1). The luminaire element (8) is provided as an element for influencing the light emitted by the light-emitting means (7) and comprises at least two functionally and materially different regions (9; 10). The regions (9; 10) of the luminaire element (8) are integrally connected to one another as a coextruded profile.