LED Holder with Stress Release Element for Thermal Stability
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Solution Overview
Problem
Lighting arrangements with LEDs face challenges in maintaining stable optical element positioning due to thermal changes, especially when materials with different coefficients of thermal expansion are used, leading to distortions and variations in light emission properties.
Innovation Solution
A lighting arrangement featuring a holder with a stress release element that divides the optical sub-holder into outer and main parts, allowing the outer parts to deform freely under thermal stress while maintaining the main part's position, thereby reducing vertical displacements and maintaining a consistent distance between the optical element and the LED, thus enhancing thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the holder structure is made rigid to maintain stable positioning of the optical element, then the positioning stability is improved, but the structure becomes sensitive to thermal expansion mismatches causing distortions
Solution Approach 1:
The holder is divided into a first holder part and a second holder part connected by a stress release element. This segmentation allows each part to respond differently to thermal stress - the first part maintains positioning stability while the second part can deform to relieve thermal stresses, preventing distortions in the overall structure.
Solution Approach 2:
The stress release element is designed with specific mechanical properties (lower stiffness, controlled deformation characteristics) compared to the rest of the holder structure. This parameter change enables the element to undergo controlled deformation under thermal stress, absorbing expansion mismatches between different materials while maintaining the overall positioning stability.
2Productivity
If the distance between optical element and LED is reduced to improve optical performance, then the light shaping efficiency is improved, but the risk of contact and brittle failure increases
Solution Approach 1:
The holder structure is designed with built-in compliance through the stress release element, which acts as a cushioning mechanism. This allows the structure to accommodate thermal expansions and contractions beforehand, preventing sudden contact between the optical element and LED that would cause brittle failure, while maintaining the optimal small distance for optical performance.
3Adaptability or versatility
If different materials with different CTE are used for holder components, then the design flexibility and optical performance are improved, but thermal expansion mismatches cause distortions
Solution Approach 1:
The holder is segmented into parts that can be made of different materials optimized for their specific functions (optical alignment, mechanical support, thermal management). The stress release element connects these heterogeneous materials, allowing each material to expand or contract according to its own CTE without causing distortions to the overall structure.
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 significantly reduces vertical displacements by a factor of 10 compared to prior art, ensuring a stable optical performance with minimal temperature sensitivity and preventing contact between the LED and optical elements, even under significant thermal expansion mismatches.
Implementation Method 1
if the structure supporting the LED and the optical element is comprised of different parts or different materials with a differing coefficient of thermal expansion (CTE), the structure may undergo distortions during negative or positive temperature increment
Data Source
Figure 1~2
Figure 3(a)~3(b)
Figure 4~5(b)
AI summary
The invention describes a lighting arrangement (1) comprising a specific holder (5) to carry an optical element (4) above a LED lighting element (2) and to a method (100) for manufacturing the lighting arrangement (2). The holder (5) comprises an optical sub-holder (51) and a connecting sub-holder (52) connecting the optical sub-holder (51) with a support member (3), where the LED lighting element (2) is arranged on. The optical sub-holder (51) comprises at least one stress release element (6, 61, 62) dividing the optical sub-holder (51) in one or more outer parts (511) connected to the connecting sub-holder (52) and a main part (512) carrying the optical element (4), where a mechanical connection (53) between the main part (512) and the one or more outer parts (511) is weakened by the stress release element (6, 61, 62) extending through the optical sub-holder (51) to enable the one or more outer parts (511) to deform freely in case of thermal stress while maintaining a main part position (P2) of the main part (512) being closer to the desired position (P1) compared to an outer part position (P3) of the one or more outer parts (511).