LED Optical Assembly with Removable Lens and Segmented Reflector

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Solution Overview

Problem

Existing LED optical assemblies face challenges in efficiently directing light from LEDs with varying light distribution characteristics and manufacturing tolerances, requiring innovative solutions for precise reflector alignment and light distribution control.

Innovation Solution

The LED optical assembly features a dual focal point reflector with a removable optical lens system, allowing for precise alignment and exchange of lenses to optimize light direction, utilizing a recessed reflector design and prismatic areas to achieve desired light distribution patterns, and incorporating a reflector bank with interchangeable reflectors and lenses to accommodate different LEDs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a fixed reflector design is used, then manufacturing precision is improved, but adaptability deteriorates

Engineering Contradiction:

Improvereflector alignment precisionVSAvoidLED configuration adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The reflector is divided into a first reflector portion and a second reflector portion that can be independently positioned and adjusted. This segmentation allows each portion to be optimized for specific LED configurations while maintaining overall manufacturing precision through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reflector incorporates adjustable elements that allow dynamic reconfiguration between different LED arrangements. The first and second reflector portions can be positioned at different orientations and angles to accommodate various LED configurations, transforming a static design into a dynamically adaptable system.

Inventive Principle:

Principle #15Dynamics

2Device complexity

If a single optical lens is used, then device complexity is reduced, but light distribution control deteriorates

Engineering Contradiction:

Improveoptical system complexityVSAvoidlight distribution control

Core Design Contradiction:

Device complexityVSIllumination intensity

Solution Approach 1:

The optical lens is divided into a first optical lens portion and a second optical lens portion, each with different optical characteristics. This segmentation enables independent optimization of each lens portion for specific light distribution requirements while maintaining relatively simple individual component designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the optical lens system are designed with different optical properties to address specific light distribution needs in different regions. The first and second optical lens portions have tailored characteristics that optimize light control for their respective functional zones.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If a removable optical lens system is used, then adaptability is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improvelens exchangeabilityVSAvoidalignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Alignment features and mounting structures are pre-configured during manufacturing to ensure precise alignment when optical lens portions are removed and reinstalled. This preliminary preparation of alignment references maintains manufacturing precision despite the removable nature of the lens system.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The alignment system incorporates mechanical features such as alignment pins, reference surfaces, or registration marks that automatically guide the optical lens portions into precise positions during assembly and reassembly, replacing complex mechanical adjustment mechanisms with simpler, more reliable alignment features.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively directs a majority of light output downward and asymmetrically, enhancing illumination coverage and flexibility in light distribution patterns, accommodating various LED configurations and improving light efficiency.

Implementation Method 1

optical lens system, allowing for precise alignment and exchange of lenses to optimize light direction

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

dual focal point reflector with a removable optical lens system, enhancing illumination coverage and flexibility in light distribution patterns

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS8672519B2LED optical assembly

Publication Date: 2014.03.18 SIGNIFY HOLDING BV

AI summary

A reflector with an alignment recess is provided. The reflector has a recess portion that receives the base of a light emitting diode. At least a portion of an outer periphery of the base of the light emitting diode is adjacent at least portions of the recess portion of the reflector.