Modular LED Luminaire Form-Fitting Alignment
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Solution Overview
Problem
Modular lamps face issues with thermal expansion causing optical defects and noise due to differing coefficients of materials, requiring a design that maintains alignment and reduces noise while allowing for easy assembly and disassembly, and maintaining a unified appearance.
Innovation Solution
The lamp employs form-fitting connections between separate components like the LED module, lens element, and reflector, with no material connection, allowing for precise alignment and thermal management, and a snap-in connection for assembly, along with punctiform contact to reduce noise and include a contact protection for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If modular construction is used with separate components, then ease of manufacture and adaptability are improved, but alignment precision deteriorates due to thermal expansion differences
Solution Approach 1:
The patent employs form-fitting connections with geometric parameters designed to accommodate thermal expansion. The connections allow for controlled movement in specific directions while maintaining precise alignment in critical optical axes, resolving the contradiction between modular flexibility and alignment precision.
Solution Approach 2:
The form-fitting connections act as intermediaries between separate modular components. These connections include features like positioning elements and tolerances that mediate the thermal expansion differences between materials while maintaining precise relative positioning of optical components.
2Stability of the object's composition
If components are mechanically connected with material connection, then structural stability is improved, but ease of repair and adaptability deteriorate
Solution Approach 1:
The luminaire is divided into separate modular components (LED module, reflector, lens) that are mechanically connected through form-fitting connections rather than permanent material bonds. This segmentation allows each component to be independently replaced or adjusted while maintaining structural stability during operation.
Solution Approach 2:
The mechanical connections are designed with controlled flexibility to accommodate thermal expansion and contraction during operation. The form-fitting connections maintain stable positioning under normal operating conditions but allow easy disassembly when needed for repair or replacement.
3Ease of operation
If form-fitting connections are used for alignment, then ease of operation is improved, but noise generation worsens due to thermal expansion
Solution Approach 1:
The form-fitting connections are designed with built-in compliance features and tolerances that cushion against thermal expansion forces before they can generate noise. The geometric design of the connections absorbs expansion stresses smoothly, preventing the stick-slip noise that would otherwise occur during thermal cycling.
4Temperature
If direct connection between LED module and device mount is made, then thermal management is improved, but ease of manufacture deteriorates due to assembly complexity
Solution Approach 1:
The reflector is designed to serve multiple functions: it provides the necessary thermal path from the LED module to the device mount while also serving its primary optical function of directing light. This multi-functionality eliminates the need for separate thermal management components, maintaining effective heat dissipation while simplifying the overall assembly process.
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 design ensures minimal optical defects, reduces noise, and enhances operational safety while allowing for easy assembly and disassembly, maintaining a unified appearance and efficient thermal management.
Implementation Method 1
LED modules, which include one or more LEDs (Light Emitting Diodes, which is understood here to mean any form of semiconductor light source)
Implementation Method 2
reflector
Implementation Method 3
lens element
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a luminaire comprising at least: a device carrier (2), an LED module (3), a lens element (4), and a reflector (5), all of which are designed as separate components and are mechanically connected in the luminaire, wherein the LED module (3) rests against the device carrier (2) by a first positive locking mechanism, and the first positive locking mechanism positions the LED module (3) in a longitudinal and transverse direction on the device carrier (2), wherein the lens element (4) and the reflector (5) interlock by a second positive locking mechanism, and the second positive locking mechanism only aligns the lens element (4) and the reflector (5) relative to each other, and wherein the LED module (3) is aligned relative to the reflector (5) by a third positive locking mechanism, and wherein the reflector (5) is snapped into the device carrier (2).