Modular Lamp Insert With Pressing Reflector Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lamp inserts are difficult to manufacture and assemble, lack mechanical stability, and require complex processing for light-guiding structures, while also failing to securely fasten and thermally connect lighting modules effectively.
Innovation Solution
A lamp insert design featuring a carrier element with reflector modules that exert contact pressure on a lamp module, providing mechanical stability and thermal connection, and allowing for separate optimization of reflector and carrier elements, with optional elastic areas and snap connections for easy assembly and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the carrier element is processed to create light-directing structures through painting or other processing, then the light distribution can be controlled, but the manufacturing complexity and processing time increase
Solution Approach 1:
The light-directing function is segmented from the carrier element by using separate reflector modules that can be independently manufactured and then attached to the carrier element. This eliminates the need to process the carrier element itself for light-directing structures, simplifying its manufacturing while maintaining controllable light distribution through the modular reflectors.
Solution Approach 2:
The light-directing structures are extracted as separate reflector modules from the carrier element. These modules can be produced independently using optimal manufacturing processes for their specific function, while the carrier element is produced separately without complex processing, thus reducing overall manufacturing complexity.
2Stability of the object's composition
If the light source module is securely fastened to the carrier element, then mechanical stability is improved, but the thermal connection may be compromised due to insufficient contact
Solution Approach 1:
The fastening function is segmented from the thermal connection function by introducing separate fastening elements that do not interfere with the thermal path. The reflector modules serve as fastening elements that apply pressing force to secure the light source module mechanically while maintaining direct contact between the heat-generating components for thermal connection.
Solution Approach 2:
The reflector modules act as intermediary elements that transmit both mechanical pressing force for secure fastening and thermal energy from the light source. By positioning these reflector modules between the light source module and carrier element, they simultaneously provide mechanical stability and maintain thermal connection without requiring separate fastening mechanisms.
3Illumination intensity
If painting or other processing is applied to the carrier element to create light-directing structures, then the light guidance function is achieved, but the manufacturing time and cost increase
Solution Approach 1:
The light guidance function is segmented into separate reflector modules that can be manufactured independently using simple, fast processes. These modules are then attached to the carrier element, eliminating the need for time-consuming painting or processing of the carrier element itself, thus improving overall manufacturing productivity.
Solution Approach 2:
The reflector modules are prepared in advance as pre-fabricated components with their light-directing surfaces already formed. This preliminary preparation allows for parallel manufacturing of multiple components and eliminates on-site processing time, speeding up the overall assembly process.
4Ease of operation
If the carrier element and light source module are integrated as a single component, then assembly is simplified, but the ability to optimize each component independently is reduced
Solution Approach 1:
The system is segmented into modular components (carrier element, light source module, reflector modules) that can be independently optimized for their specific functions. The standardized interfaces between these modules enable simple assembly while preserving the flexibility to optimize each component separately using the most suitable materials and manufacturing processes.
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 design simplifies manufacturing, ensures secure fastening and thermal management of lighting modules, maintains mechanical stability, and allows for adjustable contact pressure, enabling efficient assembly and alignment while maintaining safety and performance.
Implementation Method 1
The reflector modules are attached to the carrier element and exert a pressing force on the light source module in the direction of the carrier element
Implementation Method 2
a further element, in particular a thermally conductive film, can be arranged between the light source module and the support element
Implementation Method 3
The reflector modules can be made of a reflective material, have a reflective surface coating, or be provided with one or more reflective elements
Data Source
Figure 1~2
Figure 3~4
AI summary
The insert has a light module (3) and reflector modules (4) arranged on a carrier element (2), where the light module comprises multiple lighting units (31) e.g. LED and/or organic LED. The reflector modules are releasably fastened at the carrier element by a snatching-, a wedging- and/or a detent connection. The reflector modules are made from plastic and exert a contact force on the light module toward the carrier element. The reflector modules rest against the light module over a resilient region such as soft lip (41). The carrier element is made of metal such as aluminum.