LED Lighting Module With Flexible Optical Component and Rigid Carrier
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Solution Overview
Problem
Existing LED lighting fixtures face challenges in manufacturing complexity and cost due to weak bonding between components, and the need for waterproofing to protect against outdoor elements, particularly moisture, which can lead to fixture failure.
Innovation Solution
A lighting module design featuring a substrate with LEDs, a one-piece optical component made of flexible material, and a rigid carrier with reflective properties, along with a gasket for a watertight seal, which simplifies manufacturing and enhances protection against environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional separate lens components are manufactured and preassembled into the carrier, then each lens can be individually positioned, but the bonding between components becomes weak and manufacturing complexity increases
Solution Approach 1:
The patent merges multiple separate lens components into a single integrated optical component made of flexible material. This optical component contains multiple optical elements (lenses) that are permanently formed within the flexible material matrix, eliminating the need for separate manufacturing and assembly of individual lenses. The flexible material is then stretched over the LED array, causing the optical elements to self-position over each LED, achieving precise alignment without complex assembly processes.
Solution Approach 2:
The optical component is segmented into multiple optical elements (lenses) that are individually formed within the flexible material. Each optical element corresponds to a specific LED position, allowing individual positioning and optimization of each lens while maintaining the benefits of a unified structure. This segmentation enables precise light control for each LED without requiring separate component assembly.
2Strength
If traditional separate lens components are used with injection molding, then lenses can be secured to the carrier, but bonding strength becomes weak and manufacturing cost increases
Solution Approach 1:
The invention combines the optical elements, flexible material, and carrier into a unified assembly process. The flexible material with embedded optical elements is stretched directly over the LED array and secured to the carrier in a single operation, eliminating multiple bonding steps. This integrated approach creates stronger bonds between components and reduces manufacturing costs by eliminating the need for separate injection molding and assembly operations for each lens.
Solution Approach 2:
The flexible material with optical elements embedded therein serves its own positioning function when stretched over the LED array. The optical elements automatically align with the LEDs through the stretching process, eliminating the need for complex alignment and bonding operations. This self-positioning capability strengthens the bonding between optical elements and LEDs while simplifying the manufacturing process.
3Ease of manufacture
If the luminaire is not waterproof, then manufacturing is simpler, but moisture penetration causes fixture failure in outdoor environments
Solution Approach 1:
The flexible material that forms the optical component also serves as a waterproof barrier. This flexible film encapsulates the LED array and optical elements, creating a sealed environment that prevents moisture penetration while maintaining the ability to conform to the fixture geometry. The flexible nature of this shell allows for simpler manufacturing compared to rigid waterproof enclosures, as it can be stretched and secured in place to create the seal.
Solution Approach 2:
The flexible material performs multiple functions simultaneously: it serves as the structural base for the optical elements, provides the optical interface for light extraction, and creates the waterproof seal. This multi-functionality eliminates the need for separate waterproofing components, simplifying manufacturing while ensuring reliable protection against moisture in outdoor environments.
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 provides improved light emission efficiency, mechanical strength, and a waterproof seal, reducing manufacturing complexity and costs while ensuring the fixture's durability in harsh environments.
Implementation Method 1
Each of the plurality of optical elements may include a parabolic shaped optical structure such that an LED may be positioned at a focus of the parabolic shaped optical structure.
Implementation Method 2
The gasket may be formed from material such as, without limitation, silicone, thermoplastic elastomers, rubber, or foam.
Implementation Method 3
the rigid carrier may be configured to provide reflective properties for light emitted by the plurality of LEDs
Data Source
AI summary
A lighting module is disclosed. The lighting module includes a substrate for holding a plurality of light emitting diodes (LEDs), optical component, and a rigid carrier configured to interface with the substrate and seal the optical component to the substrate. The optical component includes a plurality of optical elements, each positioned to be located over one of the plurality of LEDs and a peripheral portion. The peripheral portion is configured to wrap around a side wall of the rigid carrier.