Flexible Polymeric Lens Mechanical Fastening for LED Strip Mounting
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Solution Overview
Problem
Existing luminaire fixtures face challenges with rigid lenses and housings that limit length, create seams in long installations, and rely on unreliable adhesive mounting methods, leading to logistical issues and poor light distribution.
Innovation Solution
A novel luminaire lens and housing system that uses a flexible, extruded polymeric lens body with mechanical fastening capabilities, allowing seamless integration and modular construction for continuous lengths without seams, using a lens body with an interior section and sidewalls to apply pressure to the light strip, eliminating the need for additional components and polymeric jackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid polymeric lenses are used in traditional luminaire fixtures, then structural strength is improved, but flexibility in length and configuration is limited
Solution Approach 1:
The patent applies this principle by using a flexible polymeric lens body that can be bent and configured in various shapes. The lens is designed with sufficient flexibility to wrap around mounting brackets and conform to different housing configurations, while maintaining its optical function. This resolves the contradiction by providing both structural integrity and adaptability in length and configuration.
Solution Approach 2:
The patent employs parameter changes by utilizing the viscoelastic properties of the polymeric lens material. The lens can be deformed during installation to fit various configurations, then maintains its shape under operational conditions. This allows the same lens design to accommodate different lengths and arrangements, achieving versatility without sacrificing structural strength.
2Manufacturing precision
If rigid lenses are used, then manufacturing precision is improved, but ease of installation and seamless integration is worsened
Solution Approach 1:
The flexible polymeric lens can be easily deformed during installation to fit into various housing configurations and mounting bracket arrangements. After installation, the lens maintains its shape to provide seamless integration and uniform light distribution. This flexibility dramatically simplifies the installation process compared to rigid lenses while preserving manufacturing precision through controlled deformation.
Solution Approach 2:
The patent applies dynamics by designing the lens to transition from a deformable state during installation to a stable state during operation. The lens can be dynamically adjusted to fit different configurations, then locks into place to provide consistent optical performance. This dynamic behavior enables easy installation while maintaining precision.
3Ease of operation
If adhesive mounting methods are used for LED strips, then ease of installation is improved, but reliability under environmental factors is worsened
Solution Approach 1:
The patent replaces the chemical adhesive mounting system with a mechanical fastening system. The flexible lens body itself acts as the mounting mechanism, using its elasticity and deformability to mechanically secure the LED strip in place. This mechanical approach provides superior reliability under environmental factors such as temperature changes, moisture, and vibration, while still maintaining ease of installation through the lens's flexibility.
4Reliability
If additional mounting components and polymeric jackets are used, then mounting reliability is improved, but device complexity is worsened
Solution Approach 1:
The patent merges multiple functions into the single lens component. The lens simultaneously provides optical function, structural support, mechanical fastening, and environmental protection. By integrating the mounting function directly into the lens body, the patent eliminates the need for separate mounting brackets, adhesive layers, and protective jackets, thereby reducing overall device complexity while maintaining or improving reliability.
Solution Approach 2:
The flexible polymeric lens is designed as a multi-functional component that performs multiple roles: optical transmission, structural support, mechanical fastening of the LED strip, and environmental sealing. This universal design eliminates the need for multiple specialized components, reducing system complexity while enhancing mounting reliability through the lens's inherent properties.
Data Source
AI summary
The present technology is a luminaire lens and housing system for mechanically fastening of a light strip to a luminaire housing via a lens body. The system can include a luminaire housing formed from extruded modular luminaire housing sections assembled together, a mounting bracket mountable to the housing sections, and a lens body mountable to the mounting bracket. The mounting bracket includes a generally U-shape configuration capable of receiving the light strip and the lens body. The lens body can be a flexible polymeric lens of continuous length for the entire length of the luminaire housing. An interior section of the lens body includes legs receivable in depressions defined in the mounting bracket for retention thereof. The lens body is configured to contact and apply mechanical pressure to the light strip thereby securing the light strip in the mounting bracket or in the luminaire housing.