Headphone Light Guiding Unit with Segmented Optical Surfaces
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Solution Overview
Problem
Conventional headphones have a low usage rate of light sources due to inefficient light refraction and a complex, costly assembly process for the light emitting device, which increases manufacturing costs and makes reworking difficult.
Innovation Solution
A light emitting device with a light guiding unit featuring an incident surface, emitting surface, refracting surfaces, and reflecting surfaces, along with a light transmitting column, that allows for improved light refraction and reflection to increase light transmission rates, and a buckling arm and positioning wall design for tool-free assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional light guiding element with simple structure is used, then assembly process is simple, but light source usage rate is low due to inefficient light refraction
Solution Approach 1:
The light guiding element is segmented into multiple functional surfaces: incident surface for light entry, first refracting surface for initial light direction control, first reflecting surface for light redirection, second refracting surface for further light direction adjustment, and second reflecting surface for final light reflection. This segmentation allows each surface to perform a specific optical function, improving overall light transmission efficiency while maintaining manufacturing simplicity through modular design
Solution Approach 2:
The patent employs curved and angled surfaces instead of flat planes. The incident surface, refracting surfaces, and reflecting surfaces are designed with specific curvatures and angles to optimize light refraction and reflection paths. This curvature design enables more effective light gathering and direction control, increasing light source usage rate without complicating the manufacturing process
2Reliability
If hot-melt column assembly method is used, then light guiding element can be fixed, but manufacturing cost increases and housing is frequently scratched
Solution Approach 1:
The patent extracts and eliminates the hot-melt column and hot-melt tool from the assembly process. Instead of using thermal adhesive methods, the light guiding element is directly integrated with the housing through precision-machined interfaces and mechanical interlocking features. This removal of the hot-melt column eliminates the need for expensive hot-melt tools, reduces manufacturing costs, and prevents housing scratches while maintaining reliable fixation
Solution Approach 2:
The patent replaces the thermal-mechanical hot-melt assembly system with a pure mechanical interference fit system. The light guiding element features precisely engineered outer dimensions that create friction-based mechanical retention within the housing, eliminating the need for thermal processes. This mechanical substitution reduces manufacturing complexity, lowers costs, and improves housing integrity
3Reliability
If hot-melt column is used for assembly, then light guiding element can be fixed, but reworkability is poor if assembly is skewed
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the light guiding element and housing design. Precision-machined locating surfaces, guide ribs, and interference-fit interfaces are pre-configured to ensure correct alignment during assembly. These preliminary actions prevent skewed installation before it occurs, ensuring proper positioning and maintaining high reworkability if adjustment is needed
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
Enhances light source usage and simplifies the assembly process, reducing manufacturing costs and improving reworkability by effectively guiding light rays to the outermost surface of the light transmitting column and allowing for tool-free assembly of the light guiding unit.
Implementation Method 1
The incident surface is an optical cambered surface... light rays emitted from the luminous unit are effectively guided to the outermost surface of the light transmitting column by virtue of refracting actions of the first refracting surface and the second refracting surface
Implementation Method 2
light rays emitted from the luminous unit are effectively guided to the outermost surface of the light transmitting column by virtue of refracting actions of the first refracting surface and the second refracting surface, and reflecting actions of the first reflecting surface and the second reflecting surface
Data Source
AI summary
A headphone includes a housing, a light emitting device and a printed circuit board. The light emitting device is mounted in the housing. The light emitting device includes a luminous unit, and a light guiding unit disposed close to the luminous unit. The light guiding unit has a base portion, an incident surface formed at an inner surface of an inner end of the base portion, an emitting surface formed at an outer surface of an outer end of the base portion, a first refracting surface, a first reflecting surface, a second reflecting surface, a second refracting surface, a light transmitting column, a positioning wall, an upper buckling arm and a lower buckling arm. The printed circuit board is mounted in the housing.