Curved Light Guide Assembly with Bendable Backing
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Solution Overview
Problem
Existing light fixtures with light guides face challenges in assembling light emitting diodes (LEDs) against the edge faces of the light guide due to manufacturing tolerances and complex geometry, leading to gaps that affect light capture and distribution.
Innovation Solution
A method involving a backing structure with flanges that allows for bending to close the gap between LEDs and the light guide, ensuring maximum light capture and distribution by positioning the light guide and reflective sheet between the flanges, with the bending process aligning LEDs with the light guide's edge faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid assembly methods are used to position LEDs against the light guide edge faces, then manufacturing precision can be maintained, but assembly complexity increases and gaps remain due to manufacturing tolerances
Solution Approach 1:
The backing structure is designed to be bendable rather than rigid, allowing it to dynamically adjust and close gaps between LEDs and light guide edge faces during assembly. This dynamic flexibility compensates for manufacturing tolerances without requiring complex precision alignment procedures.
Solution Approach 2:
The backing structure's physical state is changed from rigid to flexible/bendable, enabling it to conform to the light guide's geometry and eliminate gaps. This parameter change in structural rigidity allows for simpler assembly while maintaining precise LED positioning.
2Stability of the object's composition
If rigid backing structures are used to hold LEDs, then structural stability is maintained, but gaps between LEDs and light guide cannot be closed due to manufacturing tolerances
Solution Approach 1:
The backing structure transitions from a static rigid form to a dynamic flexible form that can bend and deform. This allows the structure to maintain overall stability while locally adapting to close gaps between LEDs and the light guide edge faces during the bending process.
Solution Approach 2:
The backing structure is designed to bend into a curved configuration that matches the light guide's geometry. This curvature enables the flanges to converge and close gaps, accommodating manufacturing tolerances while maintaining structural integrity.
3Manufacturing precision
If precise alignment of LEDs with light guide edge faces is attempted through complex assembly procedures, then manufacturing precision can be achieved, but assembly time and complexity increase
Solution Approach 1:
The backing structure is pre-designed with flanges positioned to converge during bending, so that the alignment action is built into the structure itself rather than requiring separate precise positioning steps. This preliminary structural design eliminates the need for time-consuming manual alignment procedures.
Solution Approach 2:
The bending process dynamically brings the flanges together to close gaps and align LEDs with the light guide edge faces in a single motion, rather than requiring multiple precise positioning steps. This reduces assembly time while maintaining alignment precision.
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 method ensures efficient light capture and distribution by aligning LEDs with the light guide, reducing assembly complexity and accommodating manufacturing variations, resulting in improved light fixture performance.
Implementation Method 1
Light is accepted into one or more edge faces of the light guide and transported across the light guide via total internal reflection
Data Source
AI summary
A method of assembling a light fixture includes assembling a light guide into a backing structure. The backing structure includes a sheet and first and second flanges at two opposite edges of the sheet. A row of light emitting diodes (LEDs) is installed on the first flange, positioned to direct light away from the first flange and toward the second flange, and generally parallel with the major surfaces of the flat sheet. The light guide is positioned between the flanges and against the backing structure. The width of the light guide is less than the distance between the LEDs and the second flange. The backing structure and the light guide are bent toward a bottom surface of the backing structure such that the flanges are drawn toward each other and such that the LEDs are drawn toward an input face of the light guide.