Lighting Device Monolithic Support and Optics Integration
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Solution Overview
Problem
Current lighting device manufacturing processes face challenges in creating flexible, cost-effective, and efficient solutions for producing a variety of spot designs with good thermal performance, particularly in retail lighting where speed and customization are crucial, often requiring extensive tooling and investments.
Innovation Solution
A process involving a tubular or shaped housing with a support that is smaller than the housing's inner dimension, using monolithic bodies to integrate both support and optics functions, allowing for flexible fixation through local pressure to deform the material and secure the support within the housing, enabling quick assembly without additional fixation means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional press fitting or thermal expansion methods are used to fix the support in the housing, then mechanical fixation is achieved, but production time increases and tooling costs rise
Solution Approach 1:
The support is designed with an integrated fixation element that automatically engages with the housing during assembly. The fixation element features a deformable structure that bends upon insertion and then elastically recovers to lock the support in place, eliminating the need for separate fixation steps or additional tools.
Solution Approach 2:
The patent replaces complex thermal expansion systems or multi-step mechanical press fitting with a simple elastic deformation mechanism. The fixation element utilizes material elasticity to provide both the insertion force and the locking force, substituting for elaborate mechanical fixation systems.
2Adaptability or versatility
If customized designs are engineered for specific customers, then design flexibility is improved, but tooling investments and production time increase
Solution Approach 1:
The lighting device is divided into modular components: the housing, the support with integrated fixation, and the optical elements. This segmentation allows different combinations and configurations to be assembled from standardized parts, enabling customization without requiring custom tooling for each design variant.
Solution Approach 2:
The support structure serves multiple functions simultaneously: it provides mechanical support for optical elements, conducts heat away from LEDs, and incorporates the fixation mechanism for mounting in the housing. This multi-functionality reduces the number of separate components and tooling requirements.
3Temperature
If the support is made larger to improve thermal performance, then heat dissipation is improved, but the available space in the compact housing is reduced
Solution Approach 1:
The support structure extends in multiple dimensions within the housing, utilizing vertical space and radial directions rather than only horizontal expansion. Heat sinks are configured to project upward or outward from the LED mounting plane, effectively increasing thermal dissipation surface area without consuming excessive horizontal housing volume.
Solution Approach 2:
The support with thermal management features is nested within the housing structure, with heat sink elements arranged to fit within the available internal volume. The fixation element is integrated into the support itself rather than being a separate external component, maximizing space utilization.
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 approach allows for rapid production of customized lighting devices with high thermal coupling and mechanical fixation, reducing tooling costs and enabling a wide range of designs with improved thermal performance and assembly efficiency.
Implementation Method 1
fastening the support to at least part of the shaped element by pressing with a pressing element a (deformable) fastening material against and/or into a shaped element wall of the shaped element
Implementation Method 2
pressing with a pressing element a (deformable) fastening material against and/or into a shaped element wall
Data Source
Figure 1A~1B
Figure 2~3A
Figure 3B~4
AI summary
The invention provides a lighting device element (100) comprising (i) at least one shaped element (120) selected from the group consisting of a pipe-like shaped element (120,119) and a rod-like shaped element (120,129), (ii) one or more functional elements (180) selected from the group consisting of a light source (10), electronics (20) for a light source (10), a heat sink (1401) and optics (30) for a light source (10), and (iii) a support (140) for the one or more functional element (180), wherein the lighting device element comprises at least said optics as functional element, wherein the lighting device element (100) comprises at least two monolithic bodies (170), each monolithic body (170) comprising at least part of the support (140) and at least part of the optics (30), with said at least two monolithic bodies (170) providing thereby said support (140) and said optics (30), wherein (a1) at least part of the support (140) and (a2) at least part of the one or more functional elements (180) are accommodated within and/or around the shaped element (120); wherein the support (140) and the one or more functional elements (180) are coupled; wherein (b1) the support (140) comprises at least part of a fastening material (145) and/or (b2) a support assist (160), at least partly configured within and/or around the shaped element (120), comprises at least part of the fastening material (145) and the support assist (160) comprises a receptor opening (169) hosting at least part of the support (140); wherein adjacent to a shaped element wall (121) of the shaped element (120) the fastening material (145) comprises (c1) an indentation (147) and (c2) part of the fastening material (145) is in pressed physical contact with said shaped element wall (121) and/or protruding into said shaped element wall (121) via which the support (140) is locally fixed to the shaped element (120).