Reference Frame for LED Optical Element Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In automotive lighting, achieving exact positioning of optical elements relative to LED elements is challenging due to positioning tolerance issues, which affect the illumination beam's specifications.
Innovation Solution
A lighting arrangement with a reference frame part that includes reference portions and a frame opening for precise positioning of optical elements, allowing the optical system to be referenced relative to the frame opening rather than the LED element's position, using a reference frame part with protrusions or flat parts on surfaces for alignment along three axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the optical element is positioned directly on the LED element, then the positioning tolerance accumulates with the LED chip position tolerance, but adding a reference frame part increases the device complexity
Solution Approach 1:
A reference frame part is introduced as an intermediary component between the LED element and the optical element. This reference frame part includes reference portions that provide precise positioning surfaces for the optical element, decoupling the positioning tolerance from the LED chip position tolerance. The reference frame part acts as a mediator that establishes a stable reference system independent of LED positioning variations.
Solution Approach 2:
The positioning system is segmented into separate functional components: the LED element, the reference frame part, and the optical element. The reference frame part is divided into multiple reference portions (first, second, and third reference portions) that independently define positions along different axes. This segmentation allows each component to be optimized independently and simplifies the tolerance chain.
2Measurement precision
If multiple reference portions are added for exact positioning along three axes, then the alignment precision improves, but the manufacturing complexity increases
Solution Approach 1:
Multiple reference portions for positioning along three different axes are merged into a single integrated reference frame part. This consolidation allows all reference portions to be manufactured together as one component, simplifying the manufacturing process while maintaining high alignment precision. The reference frame part combines first, second, and third reference portions that respectively define positions along different axes.
3Reliability
If the optical element is positioned relative to the LED element, then the positioning tolerances accumulate, but decoupling them requires additional reference portions
Solution Approach 1:
The reference frame part serves as a mediator that decouples the positioning relationship between the LED element and the optical element. By introducing this intermediate reference system with multiple reference portions, the optical element is positioned relative to the reference frame rather than directly to the LED element, preventing tolerance accumulation and ensuring reliable illumination beam specifications.
Data Source
Figure 1~2
Figure 3~5
Figure 6~6a
AI summary
A lighting arrangement 10 is described with an LED element 30. A reference frame part 14 comprises a frame opening 26 bordered by frame edges 28a, 28b, 28c, 28d. The LED element 30 is arranged such that light is emitted through the frame opening 26 and is partially shielded at least at a first frame edge 28b. The reference frame part further comprises reference portions 20a, 20b, 20c, 20d to define positions relative to the frame 5 opening. A first reference portion 20a, 20b is provided on a first surface portion of the reference frame part 14 arranged parallel to a light emitting surface 38 of the LED element 30. A second reference portion 20c is arranged on a second surface portion of the reference frame part 14 arranged perpendicular to the first surface portion. A third reference portion 20d is arranged on a third surface portion of the reference frame part 14 arranged 10 perpendicular to both the first and second surface portions. An optical element 12 for shaping an illumination beam 42 from light emitted from the LED element 30 through the frame opening 26 is arranged to be in contact with the reference frame part 14 at the first, second and third reference portions 20a, 20b, 20c, 20d to define a position of the optical element relative to the frame opening 26.