Elongated LED Lamp Optical Element Bending Stress Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing elongated LED lamps face challenges in cost-effective production and maintaining precise optical alignment due to temperature fluctuations, which can cause undesirable gaps and stresses between optical elements and the carrier bar.
Innovation Solution
An elongated LED lamp design featuring an optical element held under bending stress, with a slight curvature that is eliminated upon assembly, using a screw connecting element to ensure precise alignment and secure positioning, and a latching connection to prevent relative movement due to temperature changes, allowing for precise light influencing and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the optical element is rigidly fixed to the carrier element, then the alignment is stable, but temperature fluctuations cause undesirable gaps and stresses
Solution Approach 1:
The patent introduces a curved mounting surface on the optical element that changes its effective shape under bending stress. This parameter change allows the optical element to adapt to thermal expansion and contraction, maintaining contact and alignment stability while accommodating temperature-induced dimensional changes without creating gaps or harmful stresses.
Solution Approach 2:
The mounting design allows the optical element to dynamically adjust its position and shape in response to temperature changes. The curved surface enables controlled deformation that maintains optimal alignment conditions across varying thermal conditions, transforming a static rigid connection into a dynamically adaptive one.
2Manufacturing precision
If the optical element is held under bending stress with curved mounting surface, then alignment precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies curvature to the mounting surface of the optical element, which is then bent during assembly to achieve precise alignment. This curvature approach allows for fine-tuning of the optical element's position and orientation, achieving high alignment precision while the curvature itself can be integrated into standard manufacturing processes like injection molding.
3Object-affected harmful factors
If the optical element is not fixed at end regions in longitudinal direction, then temperature-induced stresses are reduced, but alignment precision may deteriorate
Solution Approach 1:
The mounting system is segmented into different zones: the curved mounting surface area that allows controlled deformation for stress relief, and the end regions that provide positional constraints. This segmentation enables the optical element to expand and contract along its length without generating harmful stresses, while still maintaining precise alignment through the curved surface mechanism.
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 design achieves precise alignment and secure positioning of the optical element relative to the LED light source, preventing gaps and stresses, while enabling cost-effective production and maintaining optical accuracy even with long optical elements exceeding 30 cm in length.
Implementation Method 1
the optical element is arranged so as to be held on the carrier element under a bending stress
Implementation Method 2
the at least one connecting element exerts a force on the optical element that acts perpendicularly to the longitudinal axis
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A luminaire has an elongated support element (1), an LED light source (5) arranged on the support element (1) for generating light, and an elongated optical element (3) extending along a longitudinal axis (L) and arranged parallel to the support element (1) for influencing the light, wherein the optical element (3) is held on the support element (1) under bending stress.