Coextruded Optical Assembly for Linear Light Fixtures
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Solution Overview
Problem
Existing LED lighting systems are costly and inefficient in manufacturing, particularly in producing large, solid-state linear light fixtures for commercial environments, as they require complex assembly and materials that are not easily scalable or cost-effective.
Innovation Solution
The development of a low-cost, solid-state light fixture with a coextruded optical assembly, where the reflector and lens portions are formed as a single thermoplastic component, allowing for efficient manufacturing and assembly by joining complimentary portions end-to-end, and incorporating an LED light source with specific wavelength groups to achieve high color rendering index (CRI) lighting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate manufacturing and assembly methods are used for reflector and lens components, then manufacturing flexibility is maintained, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The reflector and lens components are merged into a single coextruded optical assembly where the reflector forms the inner surface and the lens forms the outer surface of a unified structure. This integration eliminates the need for separate manufacturing and assembly operations, directly reducing manufacturing cost and assembly complexity while maintaining optical functionality.
Solution Approach 2:
The optical assembly utilizes composite material construction through coextrusion, combining different thermoplastic materials with distinct optical properties (reflective and transparent/translucent) into a single integrated component. This allows the reflector and lens to be manufactured as one piece, simplifying production and reducing assembly steps.
2Productivity
If coextruded optical assembly is used, then manufacturing efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The coextrusion process utilizes controlled parameter changes in thermoplastic material viscosity and flow characteristics during manufacturing. By adjusting extrusion parameters such as temperature, pressure, and material composition ratios, the process achieves precise dimensional control and optical property uniformity in the final assembled product, enabling high manufacturing efficiency without sacrificing precision.
3Loss of time
If single-piece thermoplastic component is used, then assembly time is reduced, but material selection constraints increase
Solution Approach 1:
The invention employs composite material strategies in coextrusion, combining multiple thermoplastic materials with different optical, mechanical, and chemical properties into a single integrated component. This approach provides material selection flexibility by allowing the formulation of customized material compositions that satisfy diverse performance requirements while maintaining the assembly time benefits of a single-piece construction.
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 and increases efficiency by enabling the production of large, high-quality linear light fixtures with improved light distribution and color rendering, suitable for retail or commercial environments, while maintaining a high level of performance and aesthetic appeal.
Implementation Method 1
the reflector portion of the optical assembly includes a thin skin of reflective white material on a substrate
Implementation Method 2
the lens or lens portion of the assembly includes two lens plates
Implementation Method 3
LED light source includes an LED array with at least two groups of LEDs, wherein one group, if illuminated, would emit light having dominant wavelength from 440 to 480 nm, and another group, if illuminated, would emit light having a dominant wavelength from 605 to 630 nm
Implementation Method 4
LEDS in one group are packaged with a phosphor, which, when excited, emits light having a dominant wavelength from 560 to 580 nm
Data Source
AI summary
A light fixture with coextruded components is disclosed. Embodiments of the present invention provide a solid-state light fixture suitable for use in commercial environments. A light fixture according to example embodiments of the invention includes an LED light source and a coextruded optical assembly. In some embodiments, the reflector portion of the assembly includes a thin skin of reflective material. In some embodiments, the assembly includes an interlocking mechanical interface between the reflector and lens portions of the assembly. In some embodiments, the lens portion of the assembly includes two lens plates. In some embodiments, a longer fixture can be assembled by using two, coextruded portions of an optical assembly, where these portions are adapted to be joined end-to-end. Reinforcing members can be used in the reflector and lens assembly.