Lens Assembly Tab Positioning for Uniform LED Light Distribution

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Solution Overview

Problem

Existing LED-based lighting fixtures often suffer from dark spots around the lens due to the presence of tabs that are internal to the reflector, leading to uneven light distribution and aesthetics issues.

Innovation Solution

A lens assembly with tabs that mate with receivers on a flange outside the forward opening of the reflector, ensuring that the tabs are not visible when light is emitted, and a housing that includes a diffuser and reflector to direct and mix light efficiently, preventing dark spots and enhancing light distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If tabs are positioned inside the reflector to secure the lens, then the lens is firmly attached, but dark spots appear on the lens due to tab presence

Engineering Contradiction:

Improvelens attachment strengthVSAvoiduniformity of light distribution

Core Design Contradiction:

StrengthVSIllumination intensity

Solution Approach 1:

The tabs are extracted from the interior of the reflector and repositioned to attach to the exterior surface of the reflector's flange. This removes the tabs from the light path, eliminating the dark spots they caused while maintaining their securing function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The attachment mechanism transitions from a two-dimensional interior surface attachment to a three-dimensional exterior attachment on the flange. The tabs now engage with receiver features on the outer surface, moving the attachment interface outside the optical path.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Illumination intensity

If tabs are moved outside the forward opening of the reflector, then dark spots are eliminated, but the attachment structure becomes more complex

Engineering Contradiction:

Improveuniformity of light distributionVSAvoidattachment structure complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The tab and receiver features are integrated directly into the lens and reflector structures respectively, eliminating the need for separate attachment components. This simplifies the overall assembly while achieving the goal of exterior attachment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of attaching the lens to the interior surface, the attachment is inverted to occur on the exterior surface. The tabs on the lens engage with receivers on the reflector's outer flange, reversing the conventional attachment approach.

Inventive Principle:

Principle #13The other way round (Inversion)

3Device complexity

If the lens is attached using internal tabs, then the structure is simple, but uneven light distribution occurs due to tab shadows

Engineering Contradiction:

Improveattachment structure simplicityVSAvoidlight distribution quality

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The tabs are extracted from the light path by repositioning them to the exterior of the reflector. This maintains structural simplicity while removing the source of light distribution problems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The tabs, which previously caused harmful dark spots, are repositioned to serve their attachment function without interfering with light distribution. The same structural elements are used, but their location transforms them from harmful to beneficial.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 ensures that there are no visible dark spots on the lens during operation, providing uniform light distribution and improved aesthetics by positioning the tabs outside the light-emitting area, while the diffuser and reflector enhance light mixing and directionality.

Implementation Method 1

a housing that includes a diffuser and reflector to direct and mix light efficiently

Methodology Applied

Scientific EffectLight diffusion: Diffusion

Implementation Method 2

a reflector and a lens... light emanating from the array of LEDs is directed forward through the lens

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS8882311B2Lens assembly for lighting fixture

Publication Date: 2014.11.11 LED-IP MANAGEMENT LLC

AI summary

The present disclosure relates to a lighting fixture. In one embodiment, the lighting fixture includes a reflector and a lens. The reflector includes a first flange that defines a forward opening and includes at least one tab receiver outside of the forward opening. The lens has an outer periphery and includes at least one tab that is configured to mate with the tab receiver of the first flange, such that when each tab is mated with a corresponding tab receiver, the lens is affixed to the reflector. In this arrangement, there are no dark spots visible on the lens due to the presence of the tabs when light is emanating from the lighting fixture.