LED Module Optic Alignment Notches and Detents
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Solution Overview
Problem
The alignment of multiple LEDs with the optic in lighting devices is problematic, especially during assembly and reassembly, due to rotational symmetry issues and the difficulty in differentiating between optics with varying lens dispersal angles without clear identifying features.
Innovation Solution
The use of alignment notches and detents in the module body and optic, along with visual indicia on the optic's surface, ensures correct rotational orientation and alignment of lenses with LEDs, while a high-friction surface and specific material properties prevent rotation and ensure proper light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple LEDs are spaced apart adjacent to each other in the device, then the lighting device can provide broader illumination coverage, but alignment of the optic with the underlying LEDs becomes problematic due to rotational orientation issues
Solution Approach 1:
The patent introduces asymmetric alignment features (alignment notches in the PCB and corresponding detents on the optic) that break the rotational symmetry of the system. These asymmetric features provide unique orientation references that enable precise alignment of multiple LEDs with their corresponding optical elements, resolving the alignment problem while maintaining broad illumination coverage through multiple spaced-apart LEDs.
2Adaptability or versatility
If different versions of the optic with different lens dispersal angles are used in the same holder, then the device can be adapted to different lighting requirements, but differentiating between optic versions becomes challenging without identifying indicia
Solution Approach 1:
The patent employs visual indicia including color-coded markings on the optic and corresponding alignment notches that provide visual differentiation between optic versions with different lens dispersal angles. These visual indicators enable easy identification and correct selection of the appropriate optic version for specific lighting requirements, eliminating the difficulty of differentiation.
3Ease of manufacture
If the optic is made rotationally symmetrical about its axis, then the optic design is simplified and easier to manufacture, but rotational alignment of the optic relative to the underlying LEDs becomes troublesome during assembly
Solution Approach 1:
The patent segments the alignment function from the optical function by introducing separate alignment features (notches and detents) that are distinct from the optically active portions of the component. This segmentation allows the optic to maintain its rotationally symmetrical optical design for ease of manufacture, while the separate alignment features provide the necessary rotational alignment guidance during assembly.
Data Source
AI summary
An LED module of a lighting device includes an optic that includes one or more internal lenses, which are to be rotationally aligned with corresponding LEDs held within the module. In order to correctly rotationally align the LEDs with the lenses, the module includes one or more notches in the end of the module, which line up with and receive corresponding detents formed on the exterior surface of the optic. When the optic is mounted in the module with the detents in the notches, the LEDs line up with the lenses. Additionally, the side surface of the optic includes indicia indicating a characteristic of the optic, e.g., the lens' angles.