LED Module Tool-Free Optical Assembly Clamping Ring
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Solution Overview
Problem
Existing LED modules are limited in their ability to adapt to specific requirements due to the need for precise matching of optical elements with the housing, restricting the use of different optical elements and resulting in suboptimal performance.
Innovation Solution
An LED module design featuring a clamping ring that allows for tool-free attachment of various optical elements, including reflectors and diffusers, enabling universal compatibility and easy adjustment through interchangeable clamping rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a diffusing screen is inserted and snapped into a socket-like extension of the housing, then the diffuser can be easily assembled, but the lens cannot be attached without using tools
Solution Approach 1:
The clamping ring is designed with a universal interface that can accommodate multiple optical elements (lens, reflector, diffuser) with different shapes and sizes. The clamping ring features an internal clamping surface that adapts to various optical element geometries, allowing a single component to perform multiple functions rather than requiring separate socket-like extensions for each optical element type.
Solution Approach 2:
The clamping function is extracted from the housing structure and consolidated into a separate, interchangeable clamping ring component. This allows the clamping mechanism to be optimized independently from the housing design, enabling tool-free assembly while accommodating diverse optical elements through different clamping ring variants.
2Reliability
If optical elements are precisely matched to the shape of the housing, then they can be fastened securely, but different optical elements cannot be used
Solution Approach 1:
The clamping ring serves as a universal mounting interface that can secure multiple types of optical elements (lens, reflector, diffuser) with varying shapes and sizes. The internal clamping surface is designed to adapt to different optical element geometries while maintaining secure fastening, eliminating the need for precise matching between housing and each optical element.
Solution Approach 2:
The mounting system is segmented into separate components: the housing, the interchangeable clamping ring, and the optical element. This segmentation allows the clamping ring to act as an adapter layer that provides secure fastening for diverse optical elements without requiring the housing itself to be precisely matched to each element type.
3Ease of manufacture
If only specific reflectors or diffusers are used that match the housing shape, then assembly is simplified, but the LED module cannot be adapted to specific requirements
Solution Approach 1:
The system transitions from a static, fixed mounting configuration to a dynamic, interchangeable system. Different clamping rings can be swapped on the housing to accommodate different optical element types, allowing the LED module to be adapted to specific requirements while maintaining simple assembly procedures through the consistent clamping ring interface.
Solution Approach 2:
The clamping ring is designed as a universal component that can accommodate multiple optical element types. This universality enables the LED module to be customized for different applications by simply changing the optical element and corresponding clamping ring, rather than redesigning the entire housing structure.
4Adaptability or versatility
If a clamping ring is added to enable universal mounting, then compatibility with different optical elements increases, but device complexity increases
Solution Approach 1:
The clamping function is merged into a single integrated clamping ring component that combines the mounting interface, clamping mechanism, and optical element interface. This consolidation reduces overall device complexity compared to having separate mounting structures for each optical element type, while still achieving universal compatibility.
Data Source
Figure 1
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Figure 3a~4
AI summary
The present invention relates to an LED module for tool-free assembly of optical elements comprising a housing 10, a clamping ring 20, wherein the latter is interchangeably attached to the housing, a diffuser 30, wherein the latter is clamped and secured between the housing and the clamping ring, and at least one further optical element, wherein the clamping ring 20 is designed such that it can position and secure the further optical element to the housing 10 without tools.