Lamp Reflector Design for Precise LED Positioning
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Solution Overview
Problem
Conventional lamp production is complex and costly due to the need for precise positioning of the reflector relative to the LED, which is challenging with existing methods that often result in production tolerances and deformation issues, especially when creating the entry opening using hot punch or milling techniques.
Innovation Solution
The reflector is designed with a contact surface arrangement where no part of the reflector projects downward from the contact surface, allowing for accurate manufacturing during pressing without additional post-treatment, and preloading devices secure the reflector in place without affecting optical alignment, enabling simple and precise positioning relative to the LED.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the entry opening is created using hot punch or milling techniques, then the reflector can be produced, but the reflector contact surface deforms and requires complex post-treatment
Solution Approach 1:
The reflector contact surface is designed and positioned before the entry opening is created. By determining the contact surface location in advance during the pressing process, the subsequent hot punch or milling operation does not affect its precision, eliminating the need for post-treatment while maintaining manufacturing ease
Solution Approach 2:
The reflector is divided into functionally independent zones: the reflector contact surface area and the entry opening area. This segmentation allows the entry opening to be created after pressing without affecting the contact surface, as the hot punch or milling is localized to the entry opening region only
2Manufacturing precision
If additional post-treatment steps are added to finish the reflector contact surface, then manufacturing precision improves, but production complexity and cost increase
Solution Approach 1:
The reflector contact surface is designed with sufficient precision during the initial pressing process, eliminating the need for subsequent post-treatment steps. This preliminary determination of the contact surface location and geometry ensures that no additional finishing operations are required, thereby reducing production complexity while maintaining precision
Solution Approach 2:
The problematic post-treatment step is completely removed from the production process. By designing the reflector contact surface to be unaffected by entry opening creation, the patent extracts the unnecessary post-treatment operation, simplifying the overall production process while maintaining manufacturing precision
3Ease of manufacture
If the reflector contact surface is positioned to allow entry opening creation, then ease of manufacture improves, but the contact surface precision and perpendicularity deteriorate
Solution Approach 1:
The reflector contact surface position and orientation are determined in advance during the pressing process, establishing a precise reference that is independent of subsequent entry opening creation. This preliminary positioning ensures that ease of manufacture for the entry opening does not compromise contact surface precision
Solution Approach 2:
The reflector is segmented into independent functional zones where the entry opening and contact surface are spatially separated. This allows the entry opening to be created with ease using hot punch or milling without affecting the precision of the contact surface, as each zone can be processed independently
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 approach simplifies and cost-reduces the production of lamps by eliminating the need for complex post-treatment and precise tooling, ensuring accurate reflector positioning and mechanical stability while maintaining optical alignment.
Implementation Method 1
the at least one base contact surface abuts the at least one reflector contact surface, thus preventing a movement of the base and/or reflector towards each other when the reflector is connected to the base
Implementation Method 2
a lamp with at least one LED
Implementation Method 3
the light emitted by the at least one LED that enters the reflector through the entry opening possesses the desired emission characteristics when it leaves the reflector through the exit opening
Data Source
AI summary
A lamp has an LED, a base, and a reflector. The base is rigidly connected to the LED and has a base contact surface. The reflector, which can be connected to the base, has a reflector contact surface, an entry opening, an exit opening, and a longitudinal direction (L) that runs from the exit opening to the entry opening. The reflector contact surface is arranged in the longitudinal direction (L) between the entry opening and the exit opening, and the base contact surface abuts the reflector contact surface. Thus, movement of the base and/or reflector towards each other is prevented when the reflector is connected to the base. The reflector is formed in such a way that a projection of the reflector contact surface in the longitudinal direction (L) of the reflector is free of undercuts.