Luminaire Joining Part Design for Light Extraction and Bonding
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Solution Overview
Problem
Existing luminaires with LEDs face issues of irregular adhesive coating leading to weak bonding strength, reduced airtightness, and low light extraction efficiency due to variability in mounting and bonding processes.
Innovation Solution
A luminaire design featuring a joining part with distinct thickness and inclined surfaces between the board and surrounding wall member, including a third portion inside the wall member, enhances bonding strength, airtightness, and light extraction efficiency by using a resin-based adhesive with high reflectivity particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the area of the board exposed at the inside of the surrounding wall member is reduced to improve light extraction efficiency, then light extraction efficiency is improved, but gaps are needed between LEDs or between surrounding wall member and LEDs due to variability in mounting and bonding, preventing further area reduction
Solution Approach 1:
The joining part has different thicknesses at different locations: a first thickness between the board and surrounding wall member, and a second thickness outside the surrounding wall member that is larger than the first thickness. This local variation in thickness compensates for position variability while maximizing the exposed board area for light extraction.
Solution Approach 2:
The solution moves from a two-dimensional planar joining approach to a three-dimensional structured joining part with varying thickness in the vertical dimension. The inclined surface creates a gradient thickness profile that accommodates positioning variability without compromising the exposed board area.
2Ease of manufacture
If adhesive coating amount is irregular to simplify the bonding process, then ease of manufacture is improved, but bonding strength becomes irregular and airtightness is reduced
Solution Approach 1:
The joining part is designed with a predetermined thickness profile before adhesive application. The first portion provides a controlled adhesive layer thickness, ensuring consistent bonding strength and airtightness regardless of variations in adhesive coating amount during manufacturing.
Solution Approach 2:
The second portion of the joining part with larger thickness acts as a compensatory structure that cushions against the harmful effects of irregular adhesive coating. This pre-designed thickness variation provides a margin of error that maintains bonding reliability even when adhesive application is inconsistent.
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 design improves airtightness, resistance to external stress and thermal shock, and light extraction efficiency by ensuring consistent bonding and increased reflectivity, while maintaining a compact form.
Implementation Method 1
one end face of the surrounding wall member and the board are bonded by using an adhesive
Implementation Method 2
using a resin-based adhesive with high reflectivity particles
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to luminaire, which includes a board (21) provided in a main body part (10), a light-emitting element (22) provided on a surface of the board (21), a surrounding wall member (26) provided to surround the light-emitting element (22), and a joining part (28) including a first portion (28a) which is provided between the board (21) and the surrounding wall member (26), a second portion (28b) which is provided outside the surrounding wall member (26) and covers at least a part of an outer wall of the surrounding wall member (26) and third portion (28c) which is provided inside the surrounding wall member and covers at least a part of an inner wall of the surrounding wall member, wherein a following expression is satisfied:Wc > L/2 where a width of the third portion (28c) is Wc, and a distance between the inner wall (26c) of the surrounding wall member (26) and an end face of the light-emitting element (22) is L.