Light Tunnel Notch and Chamfer Assembly
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Solution Overview
Problem
Conventional light tunnels are difficult to assemble, leading to issues with adhesive leakage and inadequate bonding force between optical elements, which affects their operability and lifespan.
Innovation Solution
The design features reflectors with notches and chamfers to prevent adhesive leakage and enhance bonding, using a housing to secure the reflectors without the need for adhesive, allowing for robust and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional adhesive bonding is used to connect optical elements, then assembly is simple, but adhesive leakage occurs and bonding force is insufficient
Solution Approach 1:
The optical elements are divided into separate components with dedicated bonding surfaces. Each optical element has a specific bonding face that interfaces with adjacent elements, allowing controlled adhesive application only at these designated locations rather than across entire surfaces, thus preventing leakage while maintaining bonding strength.
Solution Approach 2:
A bonding structure acts as an intermediary between optical elements, providing a dedicated interface for adhesive application. This intermediate bonding structure includes features like bonding ribs or flanges that guide adhesive placement and distribute bonding force, preventing direct adhesive contact with non-bonding surfaces and eliminating leakage issues.
2Strength
If adhesive is applied to bond optical elements, then elements are connected, but assembly gap control is difficult and adhesive leakage occurs
Solution Approach 1:
The bonding surfaces are pre-formed with specific geometric features during manufacturing, such as recesses, ribs, or tapered interfaces. These pre-formed features guide the assembly process and control the gap between optical elements before adhesive application, ensuring consistent spacing and preventing adhesive from migrating to unintended locations.
Solution Approach 2:
The bonding interface has localized specific properties different from other surfaces, such as increased roughness, coating, or geometric features like protrusions or recesses. This local differentiation ensures adhesive remains at the bonding interface only, providing precise gap control while maintaining strong bonding force at the designated location.
3Ease of manufacture
If conventional light tunnel structures are used, then assembly is straightforward, but they are not robust and have short lifespan
Solution Approach 1:
The light tunnel structure combines multiple materials with complementary properties, such as combining rigid structural components with flexible sealing elements, or using coated surfaces that provide both mechanical strength and chemical resistance. This composite approach creates a more robust structure that resists degradation from heat, moisture, and mechanical stress, extending lifespan while maintaining assembly ease.
Solution Approach 2:
The design incorporates protective features that prevent damage before it occurs, such as rounded corners to prevent stress concentration, protective coatings that resist environmental degradation, and tolerance features that accommodate assembly variations. These beforehand protective measures prevent premature failure and extend the operational lifespan of the light tunnel.
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 results in a more robust light tunnel or funnel with increased bonding force and reduced assembly time, eliminating adhesive leakage and light leakage, while maintaining high-temperature stability.
Implementation Method 1
an adhesive applied to at least one junction between (A) the first or second primary side face of either the first reflector or the second reflector; and (B) the outer face of the third reflector or the fourth reflector
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
AI summary
Light tunnels, methods for forming a light tunnel, and apparatuses including light tunnels are disclosed herein. A light tunnel includes a plurality of reflectors cooperatively engaging with one another by a series of notches therein. The inner edges of the reflectors are chamfered to improve ease of assembly and decrease chipping of the edges during assembly. An adhesive can be applied at junctions between the reflectors on their outer surfaces. This construction eliminates or retards light leakage and adhesive leakage.