Elastic Retaining Element for Optical Element Fixation in Lighting Modules
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Solution Overview
Problem
Existing lighting modules face challenges in achieving a secure and damage-free fixation of optical elements to the housing module, leading to suboptimal light entry and luminous flux, while also being costly and time-consuming to assemble.
Innovation Solution
A lighting module design featuring an elongated U or V profile housing module with a rear wall section and side wall sections, incorporating an LED module and an optical element held by an elastically deflectable holding element that ensures a predetermined relative geometric arrangement, reducing production costs and assembly time through a simplified assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fixation methods (screws, clamping components) are used to secure the optical element, then the optical element can be fixed to the housing module, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The retaining element is integrated into the housing module as a single piece structure, combining the functions of mechanical support and optical element retention. This eliminates the need for separate clamping components and reduces the number of parts, thereby simplifying the assembly process while maintaining secure fixation of the optical element
Solution Approach 2:
The retaining element features an elastic deflection capability that allows it to automatically adapt to the optical element during assembly. The elastic properties enable the retaining element to self-adjust and secure the optical element without requiring additional tools or complex assembly operations, reducing assembly time and complexity
2Ease of manufacture
If multiple separate components are used for assembly, then each component can be optimized independently, but manufacturing costs and assembly time increase
Solution Approach 1:
The housing module and retaining element are designed as integrated components that can be manufactured together or pre-assembled as a unit. This reduces the total number of parts that need to be handled during assembly, thereby increasing assembly speed and productivity while still allowing for independent optimization of the integrated structure during the design and manufacturing phase
3Productivity
If the optical element is loosely fixed, then assembly is simple and quick, but light entry and luminous flux are suboptimal
Solution Approach 1:
The elastic retaining element automatically adjusts its position and applying force based on its own mechanical properties when the optical element is inserted. This self-adjusting mechanism ensures that the optical element is securely held in the optimal position for light entry and luminous flux without requiring complex adjustment procedures, thereby maintaining high assembly speed while achieving optimal optical performance
Solution Approach 2:
The elastic properties of the retaining element allow it to change its physical state (deflection amount) based on the insertion of the optical element. This parameter change enables the retaining element to provide the necessary holding force for optimal optical alignment while maintaining a simple and quick assembly process
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
The solution provides a secure, cost-effective, and efficient assembly of lighting modules with optimized light entry and luminous flux, independent of component tolerances, by using an elongated housing module with a holding element that ensures precise geometric alignment and secure fixation of the optical element.
Implementation Method 1
a plurality of elastically deflectable and longitudinally spaced elements of the retaining element bear resiliently against the optical element to fix the relative position of the optical element to the retaining element or housing module
Data Source
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AI summary
The invention relates to a lighting module with an elongated housing module in the form of a U- or V-profile, comprising a back wall section and side wall sections spaced apart by the back wall section, as well as an open longitudinal section formed between the side wall sections; an LED module with an elongated LED carrier and a plurality of LEDs electrically connected and arranged longitudinally on the LED carrier, wherein the LED module rests against the inside of the back wall section of the housing module; an optical element inserted into the open longitudinal section of the housing module, which is at least partially received by the housing module and arranged between the side sections; and a retaining element operatively connected to the optical element for holding the optical element in the housing module with a predetermined relative arrangement to the LED module.The invention further relates to a method for manufacturing such a lighting module.