LED Package Protrusions for Housing Alignment
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Solution Overview
Problem
Existing LED packages face challenges in maintaining optical performance, particularly brightness and luminous flux, due to manufacturing tolerances when additional parts like optical elements or covers are added, leading to scattered light and reduced accuracy.
Innovation Solution
An LED package design featuring optical elements and covers with detectable marks aligned to a common reference mark, allowing for precise alignment without adding manufacturing tolerances, and using a thermal barrier to manage heat without affecting optical performance, enabling improved accuracy and optical performance without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional parts like optical elements or covers are provided in the LED package, then the functionality and protection are improved, but the optical performance (brightness and luminous flux) deteriorates due to manufacturing tolerances causing scattered light
Solution Approach 1:
The patent applies preliminary action by pre-positioning alignment marks on the optical element and cover before assembly. These marks are detected by an optical system that guides the positioning process, ensuring that the optical element and cover are aligned with respect to the LED before final assembly. This preliminary alignment preparation prevents scattered light and maintains optical performance while allowing additional protective components to be added.
2Adaptability or versatility
If additional parts like optical elements or covers are provided in the LED package, then the functionality and protection are improved, but the manufacturing precision deteriorates due to accumulated manufacturing tolerances
Solution Approach 1:
The patent uses alignment marks as intermediary reference features that mediate the positioning between different components. The optical element includes first alignment marks and the cover includes second alignment marks, which are detected by an optical system to establish precise relative positioning. These intermediary marks eliminate the need for direct mechanical alignment between the optical element and cover, reducing the accumulation of manufacturing tolerances while enabling additional functional parts to be integrated.
3Manufacturing precision
If the optical element and cover are aligned with respect to the same reference mark, then the manufacturing precision is improved, but the device complexity increases due to additional alignment marks and optical detection systems
Solution Approach 1:
The patent applies self-service by enabling the optical element and cover to self-align using their own built-in alignment marks. The optical detection system automatically detects these marks and guides the positioning process without requiring complex external alignment apparatuses or manual intervention. The alignment marks themselves carry the information needed for precise positioning, making the system self-sufficient and reducing overall complexity despite the added functionality of multiple components.
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 solution enhances manufacturing accuracy and optical performance while reducing scattered light, allowing for cost-effective production with existing machinery, and enabling precise alignment and assembly of LED packages in motor vehicle lamps.
Implementation Method 1
the optical element comprises at least one first optical detectable mark and the cover comprises at least one second optical detectable mark, whereby the optical element and the cover are arranged and aligned both with respect to the same reference mark by means of the first mark and the second mark
Data Source
AI summary
A LED package (10) for use in a lamp as well as a method for manufacturing such kind of a LED package (10) are disclosed, wherein the LED package (10) comprises at least one LED (16), an optical element (18) for guiding light emitted by the LED (16), and a cover (26) for covering, at least partially, electrical components (20, 22, 24) connectable to the LED (16). The cover (26) includes three protrusions (38) that form the highest points on the package. The protrusions (38) abut a surface in a housing for accurately positioning the LED package relative to a lens (52) in the housing. The LED package (10) may be spring-loaded. Side protrusions (28) of the cover (26) additionally help to position the package within the housing.