LED-Light Mixing Rod Contact Assembly Without Air Gaps
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Solution Overview
Problem
Conventional optical devices, such as light fixtures, often feature an air gap between the LED and the light mixing rod, which can lead to inconsistent optical effects due to varying gap thickness and reduced light transmission efficiency.
Innovation Solution
The optical device eliminates the air gap by pressing the light mixing rod against the LED, utilizing a resilient member like springs to maintain contact, ensuring consistent light transmission and reducing manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an air gap is maintained between the LED and the light mixing rod, then the LED glass cover is protected from contact and degradation, but the light transmission efficiency is reduced and optical effects become inconsistent
Solution Approach 1:
The patent introduces a transparent adhesive layer as an intermediary substance between the LED glass cover and the light mixing rod. This adhesive layer serves as a mediator that allows direct contact and optimal light transmission while protecting the fragile LED glass from mechanical stress and degradation, thus resolving the contradiction between protection and efficiency
Solution Approach 2:
The patent merges the protective function and the light transmission function into a single integrated solution by using the transparent adhesive layer that simultaneously protects the LED glass and enables direct optical contact, eliminating the need for a separate air gap and achieving both protection and efficiency
2Reliability
If an air gap is used between the LED and the light mixing rod, then the LED is protected from contact, but variations in gap thickness lead to inconsistent optical effects across devices
Solution Approach 1:
The transparent adhesive layer acts as a mediator that standardizes the interface between LED and light mixing rod, providing a consistent thickness that eliminates optical effect variations while still protecting the LED glass from direct contact and mechanical degradation
Solution Approach 2:
The patent changes the physical state of the interface from an air gap (variable thickness) to a solid adhesive layer (controlled, consistent thickness), thereby standardizing the optical path and ensuring consistent optical effects across all devices while maintaining LED protection
3Loss of energy
If the light mixing rod is pressed against the LED, then light transmission efficiency is improved, but the LED glass cover may shatter due to vibration and mechanical stress
Solution Approach 1:
The transparent adhesive layer serves as a protective intermediary that allows the light mixing rod to be pressed against the LED for optimal light transmission while absorbing and distributing mechanical stresses and vibrations, preventing the LED glass from shattering
Solution Approach 2:
The patent applies a cushioning effect beforehand by using the compliant transparent adhesive layer that anticipates and absorbs mechanical stresses and vibrations before they can reach the LED glass, preventing shattering while maintaining contact pressure for efficient light transmission
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 configuration enhances the consistency of optical effects across different devices, improves light transmission by eliminating air gaps, and provides better protection for the LED during device actuation.
Implementation Method 1
A resilient member, such as one or more springs, may maintain the face-sharing contact between the LED and the light mixing rod throughout actuation of the optical device
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
Systems are provided for an optical device. The optical device includes a light emitting diode in face-sharing contact with a light mixing rod. A resilient member is configured to maintain the light mixing rod in face-sharing contact with the light emitting diode throughout a range of motion of the optical device.