LED Light Assembly Lens Alignment Thermal Expansion
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Solution Overview
Problem
Existing grid light arrangements face issues with glare and manufacturing tolerances due to temperature fluctuations and large plastic part tolerances, leading to undesirable light output and alignment problems with lenses and LED light sources.
Innovation Solution
The arrangement features independent lens elements positioned by pin-like positioning elements relative to the circuit board, forming lens element groups that can absorb thermal expansions without affecting alignment, and a grid element that surrounds the circuit board for protection, with a carrier element for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lenses are integrated into the raster element as a single piece, then manufacturing is simplified, but manufacturing tolerances become large and alignment precision deteriorates
Solution Approach 1:
The lens assembly is divided into multiple independent lens elements that can be manufactured separately and then assembled together using positioning elements. This segmentation allows each lens element to be manufactured with high precision independently, while the positioning elements ensure accurate alignment during assembly, resolving the contradiction between manufacturing simplicity and alignment precision.
2Illumination intensity
If lenses are made of plastic material to influence light output, then optical properties are improved, but thermal expansion causes alignment changes and reliability deteriorates
Solution Approach 1:
The patent employs positioning elements with specific geometric parameters (such as pins and corresponding recesses) that compensate for thermal expansion differences between plastic lens elements and the circuit board. These positioning elements maintain stable alignment despite temperature fluctuations, ensuring reliable optical performance while allowing the use of thermally expandable plastic materials for light control.
3Manufacturing precision
If multiple separate lens elements are used, then alignment precision is improved, but device complexity increases
Solution Approach 1:
Multiple lens elements are combined into a single integrated lens assembly unit that is positioned as one component relative to the circuit board using positioning elements. This merging approach maintains the alignment precision benefits of separate lens elements while reducing the number of individual components and simplifying the overall assembly process, thus resolving the contradiction between precision and complexity.
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 design ensures precise and stable light output by maintaining lens alignment during temperature fluctuations and provides comprehensive protection for the circuit board and LED light sources, enhancing manufacturing efficiency and optical properties.
Implementation Method 1
The positioning elements are designed and arranged in such a way that the lens elements are positioned by the positioning elements in relation to the circuit board. The positioning elements preferably include pin-like areas, with the circuit board having recesses corresponding thereto and the lens elements being positioned opposite the circuit board by the pin-like areas being arranged engaging in the recesses.
Implementation Method 2
The arrangement has lens elements and positioning elements. Each of the LED light sources is optically assigned to one of the grid areas. The lens elements are arranged such that they focus and direct the light emitted by the LED light sources through the corresponding grid areas.
Implementation Method 3
the cell-like grid areas of the grid element are formed by pot-like reflectors; the light from the LED light sources is emitted in a targeted manner via these pot-like reflectors
Implementation Method 4
an arrangement for light emission, which has a plurality of LED light sources (LED: light-emitting diode) arranged on a circuit board
Data Source
AI summary
A light emission arrangement comprises LED light sources (21, 22), a circuit board (1) on which the LED light sources (21, 22) are arranged, and a grid element (3) with cell-like grid areas (31, 32), wherein the arrangement is such that each of the LED light sources (21, 22) is optically assigned to one of the grid areas (31, 32). Furthermore, lens elements (41, 42) and positioning elements (5) are provided, which are designed and arranged such that the lens elements (41, 42) are positioned relative to the circuit board (1) by the positioning elements (5).