Lamp With Conical Reflector and Unilateral LED Array
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Solution Overview
Problem
Existing lamps with solid-state light sources, such as LEDs, face challenges in achieving uniform emission characteristics and meeting regulatory specifications for brightness, efficiency, and light diffusion, particularly in large-scale production where precise component positioning and emission determination are costly and complex.
Innovation Solution
A lamp design featuring an elongated array of solid-state light sources mounted on one side of a permeable substrate, integrated within a conical light-reflecting surface and domed element, which simplifies production and assembly while maintaining efficiency and luminous intensity distribution, adhering to ECE specifications without increasing component count or size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If arrays of light sources are mounted on both faces of a substrate to improve emission uniformity, then emission uniformity is improved, but device complexity and manufacturing difficulty increase due to precise positioning requirements
Solution Approach 1:
The patent extracts the light sources from a bilateral mounting configuration and positions them unilaterally on one face of the substrate. This simplification eliminates the complex positioning requirements associated with mounting on both faces while still achieving adequate emission uniformity through the single-sided arrangement combined with the reflector geometry.
Solution Approach 2:
The patent compensates for the unilateral mounting by utilizing the three-dimensional geometry of the reflector (conical surface) to redirect light from the single side of the substrate to achieve uniform emission patterns. This dimensional approach allows single-sided mounting to produce effects previously requiring dual-sided mounting.
2Manufacturing precision
If precise positioning of components is ensured in large-scale production, then manufacturing precision is improved, but production cost and complexity increase
Solution Approach 1:
The patent changes the mounting parameter from bilateral to unilateral, which relaxes the precision requirements for component positioning. This parameter change enables the lamp to be manufactured in large-scale production with standard precision tolerances, significantly reducing manufacturing cost and complexity while maintaining adequate performance.
3Reliability
If LED chips are arranged in array configuration to improve service life and efficiency, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple LED chips into a single integrated array structure mounted on one face of the substrate. This consolidation approach maintains the reliability benefits of using multiple chips while simplifying the overall device configuration and reducing assembly complexity compared to separate chip mounting approaches.
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
This design enhances the efficiency and luminous intensity distribution of LED lamps, ensuring compliance with ECE regulations while allowing for mass production and simplified assembly, maintaining the overall dimensions and reducing production costs.
Implementation Method 1
A lamp design featuring an elongated array of solid-state light sources mounted on one side of a permeable substrate, integrated within a conical light-reflecting surface
Implementation Method 2
integrated within a conical light-reflecting surface and domed element, which simplifies production and assembly while maintaining efficiency and luminous intensity distribution
Data Source
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AI summary
A lamp (10) that can be used, for example, as WSW retrofit lamp for motor vehicles (10) comprises a lamp body (12) extending in a first direction along a longitudinal axis (X10) between a proximal base portion (14) and a light-reflecting distal front surface (16) and extends in a direction transverse to the longitudinal axis (X10). An elongated array (22) of solid-state light sources (221), for example LED sources, is set distally with respect to the distal front surface (16) of the lamp body (12). The aforesaid elongated array (22) extends in a second direction (X22) transverse to the longitudinal axis (X10). The distal front surface (16) is a surface of revolution about the longitudinal axis (X10), for example a (frusto)conical surface. The distal front surface (16) converges from an outer edge (160) towards a vertex region (1600) adjacent to the elongated array (22) of light sources, with the longitudinal axis (X10) that intersects the aforesaid vertex region (1600).