Integrated Optical Element for LED Lamp Glare Control
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Solution Overview
Problem
Existing LED lamps require additional components like lenses and reflectors for glare control, leading to increased complexity and costs, and lack effective contact protection for LEDs.
Innovation Solution
An integrated optical element with a lens made of one material and a holding element made of another, differing in optical properties, which serves as a reflector and contact protection, allowing for a one-piece design and simplified production through overmoulding, enhancing photometric efficiency and glare control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a lens and a reflector are used separately to achieve glare reduction, then glare control is improved, but device complexity increases
Solution Approach 1:
The patent combines the lens and reflector into a single integrated optical element. The lens portion (first material) and reflector portion (second material) are merged into one component that performs both functions simultaneously, eliminating the need for separate lens and reflector assemblies while maintaining effective glare control.
Solution Approach 2:
The integrated optical element serves multiple functions within a single component: the lens portion focuses and directs light, while the reflector portion redirects light to achieve the desired beam pattern and glare control. This multi-functional design reduces the overall number of components required in the luminaire.
2Object-affected harmful factors
If a lens and a reflector are used separately, then glare control is achieved, but manufacturing cost increases
Solution Approach 1:
By merging the lens and reflector into a single injection-molded component, the patent eliminates the need for separate manufacturing processes, assembly steps, and quality control procedures for multiple parts. The integrated design reduces material costs, manufacturing complexity, and assembly costs while maintaining the required optical performance.
3Object-affected harmful factors
If lens and reflector are separate components, then optical function is achieved, but production time increases
Solution Approach 1:
The integration of lens and reflector into a single molded part eliminates assembly operations, reduces the number of components to be manufactured and inventoried, and enables faster production cycles. The one-piece construction can be produced more quickly through single-step injection molding processes.
4Object-affected harmful factors
If separate lens and reflector are used, then optical control is achieved, but the design lacks contact protection
Solution Approach 1:
The integrated optical element not only provides optical control through its lens and reflector portions but also serves as a protective cover for the LED. This multi-functional design combines optical performance with mechanical protection and contact prevention, enhancing the overall reliability and safety of the luminaire.
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 integrated optical element provides effective glare control and contact protection while reducing production costs and complexity, achieving high photometric efficiency and a cost-effective solution for LED lamps.
Implementation Method 1
the lens has a curved surface on which the light emitted by the LED or the LED group undergoes refraction
Implementation Method 2
the holding element opens up the possibility of realizing a reflector function of the optical element
Data Source
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AI summary
The invention relates to an optical element for a lamp and a corresponding lamp. The optical element comprises at least one lens element (1) made of a first material and a retaining element (2) made of a second material that differs in its optical properties from the first material. The at least one lens element (1) and the retaining element (2) are integrated such that the optical element is a single piece. For example, the retaining element (2) is formed by overmolding the at least one lens element (1). The retaining element (2) enables the optical element to function as a reflector, and the integrated design allows for a manufacturing-wise advantageous one-piece construction together with the at least one lens element (1).Furthermore, due to its integrated design, the optical element can be designed as an effective touch protection element.