Lighting Housing Optical Layer Dispensing for Cost Reduction
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Solution Overview
Problem
Current methods for producing lighting device housings with optical functions, such as diffused or colored light, are costly and inefficient, especially for small production volumes, due to the complexity and material waste associated with three-component co-extrusion processes.
Innovation Solution
A bi-component co-extrusion process followed by dispensing and curing of a polymeric material to form an optical functional layer on the housing, allowing for easy modification of optical characteristics without altering the extruded base profile, which can be applied to both small-scale and large-scale production, and uses sensitive pigments by minimizing thermal impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a three-component co-extrusion process is used to produce housings with optical functions, then the housing can provide diffused or colored lighting, but the production cost increases significantly and material waste is considerable
Solution Approach 1:
The patent divides the housing production into two separate stages: first, a bi-component co-extrusion process creates the basic housing structure with transparent and reflective layers; second, an optical functional layer (containing diffusive or colored pigments) is applied separately to the extruded housing. This segmentation allows the optical function to be added without complicating the main extrusion process, reducing production cost and material waste while maintaining versatility.
2Adaptability or versatility
If a three-component co-extrusion process is used to produce housings with optical functions, then the housing can provide diffused or colored lighting, but the process becomes unsuitable for small production volumes
Solution Approach 1:
By separating the housing extrusion from the optical layer application, the patent enables flexible production scaling. The bi-component extrusion can be efficiently produced in large volumes, while the optical functional layer can be applied in varying quantities or configurations based on specific product requirements, making the process adaptable to both small and large production volumes.
3Adaptability or versatility
If the optical functional layer is directly placed on the LED surface, then optical characteristics can be modified, but the thermal impact damages sensitive colored pigments
Solution Approach 1:
The patent introduces the transparent or partially diffusive housing layer as an intermediary between the LED light source and the optical functional layer containing sensitive pigments. This intermediary structure allows the optical functional layer to be positioned away from the direct thermal influence of the LED, protecting the pigments from thermal damage while still enabling effective modification of light characteristics through the layer.
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
This method reduces production costs, minimizes material waste, ensures consistent surface quality, and allows for flexible optical adjustments, making it cost-effective for small batches and special products while maintaining high-quality optical performance.
Implementation Method 1
a method for the production of a housing (12) of a lighting device (10), comprising: extruding a profile (34) of polymeric material... and dispensing on said outer surface (14a) of said extruded profile (34) an optical functional layer (18)...
Data Source
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Figure 4~7
AI summary
A method for the production of a housing (12) of a lighting device (10), including: - extruding a profile (34) of polymeric material including a central body (14) transparent or partially diffusive having an outer surface (14a), and - dispensing on said outer surface (14a) of said extruded profile (34) an optical functional layer (18) having the ability to change one or more optical characteristics of the emitted light.