Torque-Free Lamp Assembly Spring Clamping Alignment
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Solution Overview
Problem
Existing lamp assemblies with heat sinks, base plates, and reflectors often experience misalignment due to torque applied during connection, which can lead to improper positioning of LED light sources relative to the reflector.
Innovation Solution
A torque-free connection is achieved by using a common mounting opening through the heat sink, base plate, and reflector, with a spring element and tension element that apply a clamping force without generating torque, ensuring the base plate and reflector remain aligned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded elements are used to connect the reflector to the base plate and heat sink, then a secure connection is achieved, but torque is applied causing misalignment of the base plate relative to the reflector
Solution Approach 1:
The patent replaces the threaded mechanical connection system with a frictionless clamping system using a spring element and tension element. The spring element applies continuous clamping force through a mounting opening without requiring threading, thereby eliminating torque-induced misalignment while maintaining secure connection between the base plate and reflector
Solution Approach 2:
The patent changes the connection mechanism from rigid threaded fastening to elastic spring-based clamping. The spring element's elastic properties allow it to apply consistent clamping force without generating torque, resolving the contradiction between connection strength and alignment precision by fundamentally altering the mechanical parameters of the connection system
2Stability of the object's composition
If threaded elements are tightened to secure the connection, then the connection becomes firm, but the adjusted position of the base plate is lost
Solution Approach 1:
The patent substitutes the torque-based threaded connection with a frictionless spring clamping system. The spring element maintains stable connection through continuous elastic force rather than rigid threading, allowing the base plate to maintain its adjusted position without the misalignment caused by tightening torque
Solution Approach 2:
The spring element acts as an intermediary between the tension element and the clamped components. It translates tension into controlled clamping force while preventing direct torque transmission to the base plate, thereby maintaining both connection stability and position accuracy simultaneously
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 solution prevents misalignment and maintains a stable clamping force, ensuring the LED light sources are accurately positioned relative to the reflector, even under operational conditions.
Implementation Method 1
a spring element and a tension element are arranged in the opening, wherein the heat sink, the base plate, and the reflector are clamped one on top of the other with a clamping force by means of the spring element
Data Source
AI summary
A lamp assembly and to a method for assembling the lamp assembly with a heat sink, a base plate for holding at least one light source, and a reflector. A light that can be generated by the light source can be directed into this reflector and wherein the heat sink has a mounting surface on which the base plate and the reflector are arranged one on top of the other. A common mounting opening extends through the heat sink, the base plate, and the reflector, wherein a spring element and a tension element are arranged in this opening and wherein the heat sink, the base plate, and the reflector are clamped one on top of the other with a clamping force by means of the spring element. The clamping force is applied on the spring element by means of the tension element.