Integrated Light Orienting Element for 270-Degree Lamp Emission
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Solution Overview
Problem
Existing large-emitting lamps are complex and expensive due to the numerous components required for assembly and the multiple manufacturing steps involved.
Innovation Solution
A lamp component with a large emission angle of 270-360 degrees, comprising a source region for an LED light source, a light output surface, a light orienting element that integrates the functions of a reflector and lens, and a housing formed by co-extruded parts, allowing for fewer components and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple components (reflector, lens, support, housing) are assembled to form a large-emitting lamp, then the lamp achieves a large emission angle of 270-360 degrees, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the functions of the reflector and lens into a single integrated light orienting element. This element includes a first portion with a reflective surface and a second portion with a refractive surface, eliminating the need for separate reflector and lens components while achieving the same optical functionality for large-angle light distribution
Solution Approach 2:
The light orienting element serves multiple functions simultaneously: it reflects light from the LED source, refracts light to control beam direction, and integrates structural support functions. This multi-functional design reduces the overall component count while maintaining the large emission angle performance
2Illumination intensity
If multiple components and assembly steps are used to create a large-emitting lamp, then the lamp achieves large emission angle performance, but the manufacturing cost increases
Solution Approach 1:
The integrated light orienting element combines multiple optical functions into one component, reducing the number of assembly steps required. Instead of separately assembling reflectors, lenses, and supports, the invention uses a single integrated element that can be installed as one unit, thereby reducing labor costs and assembly complexity
Solution Approach 2:
The light orienting element is divided into functional portions (reflective portion and refractive portion) that can be manufactured using different processes or materials, then integrated into a single component. This segmentation allows for optimized manufacturing of each portion while achieving cost savings through reduced assembly operations
3Productivity
If a light orienting element with reflective and refractive surfaces is used, then light is effectively oriented towards the output surface, but scattered light increases glare
Solution Approach 1:
The light orienting element employs different optical properties in different portions: the first portion has a reflective surface optimized for directing light in certain directions, while the second portion has a refractive surface with specific optical characteristics. This local differentiation of optical properties allows effective light orientation while controlling glare by directing scattered light away from viewing angles
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 lamp component simplifies manufacturing, reduces costs, and maintains a large emission angle while minimizing scattered light, thereby improving glare ratings and light distribution uniformity.
Implementation Method 1
a light orienting element configured to receive light from the source region and to orient the received light towards the light output surface
Implementation Method 2
the light orienting element may have a reflection layer that is arranged to deflect a fraction of the light towards the light output surface
Implementation Method 3
the light orienting element may be configured i) to deflect a major fraction of the light towards the light output surface, and ii) to refract a minor fraction of the light towards the at least one housing sidewall
Data Source
Figure 1~2
Figure 3~5
Figure 6~10
AI summary
The invention relates to a lamp component (1) for forming a lamp (101) and to a manufacturing method for manufacturing a lamp component for forming a lamp (101), wherein the lamp component (1) has: - a source region (2) to receive an LED light source (10), - a light output surface (4) to output light, - a light orienting element (6) to orient the received light towards the light output surface (4), and - a housing (8) to position the light orienting element (6) with respect to the source region (2), with a housing sidewall (14) to let light pass through it. The light orienting element (6) i) deflects a fraction of the light towards the light output surface (4) so as to produce direct light, and ii) it refracts a fraction of the light towards the at least one housing sidewall (14) so as to produce indirect light. The light orienting element (6) is formed by a first extruded part extending in an extrusion direction. The housing (8) is formed by a second extruded part extending in the extrusion direction.