Modular Optical Module Assembly via Ultrasonic Welding
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Solution Overview
Problem
Existing luminaire systems require costly and time-consuming design of specific printed circuit boards (PCBs) and optical plates for each application, limiting flexibility and increasing stockkeeping requirements.
Innovation Solution
A method for assembling optical modules in a modular manner using a frame with openings, where optical modules are welded to the frame, allowing for flexible selection and arrangement of optical modules based on desired light distribution, and enabling easy assembly of a securely assembled optical plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If specific PCB and optical plate designs are created for each luminaire application, then the desired light distribution and photometry can be achieved, but the design process becomes costly and time-consuming with extensive stockkeeping requirements
Solution Approach 1:
The optical plate is divided into multiple interchangeable optical elements that can be independently selected and arranged. Each optical element can be designed with specific optical properties, and they are mounted on a standardized PCB grid, allowing customization without redesigning the entire optical plate.
Solution Approach 2:
A universal PCB design with standardized mounting positions and interfaces is created that can accommodate different combinations of optical elements. This single PCB design serves multiple luminaire applications by simply changing the optical element configuration, eliminating the need for application-specific PCB designs.
2Ease of operation
If interchangeable optical elements are used on a standardized PCB, then flexibility and ease of assembly are improved, but the secure assembly and positioning precision of optical elements may be compromised
Solution Approach 1:
The assembly system is segmented into standardized components (PCB, optical elements, mounting structure) with dedicated interfaces. Each component has specific engagement features that ensure proper positioning and secure connection while maintaining ease of assembly through modular design.
Solution Approach 2:
Traditional mechanical fastening methods are replaced with ultrasonic welding technology that creates strong, permanent bonds between optical elements and the PCB. This substitution maintains ease of assembly through automation while ensuring high assembly security and positioning precision through controlled welding parameters.
3Productivity
If modular optical modules are welded to a frame, then assembly speed and manufacturing accuracy are improved, but the device complexity increases
Solution Approach 1:
Multiple optical elements and their mounting structures are merged into integrated optical modules that are pre-assembled and tested. These modules are then welded as single units to the frame, reducing the number of assembly steps and improving speed while the modular nature maintains flexibility for different configurations.
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 fast and accurate manufacturing of optical assemblies with high flexibility in light patterning, reducing costs and simplifying stockkeeping by enabling modular design and assembly.
Implementation Method 1
The plurality of optical modules is welded to the frame
Implementation Method 2
The welding comprises welding, for each optical module, the transparent portion to the opaque portion
Data Source
AI summary
Example embodiments relate to methods for assembling optical modules of a luminaire and optical assembly. One example method includes providing a frame with at least one opening. The method also includes providing a plurality of optical modules to the frame, each optical module of the plurality of optical modules being provided to an opening of the at least one opening. Additionally, the method includes providing a support means to each of the plurality of optical modules and/or to each of the at least one opening. Further, the method includes assembling the plurality of optical modules to the frame by plastically reshaping a material portion in contact with the frame and the optical module. When the optical module is assembled to the frame, a first bottom surface of the optical module is substantially at a same level as a second bottom surface of the frame.