Monolithic 3D Printed Lighting Diffuser
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Solution Overview
Problem
Conventional lighting systems with complex diffuser geometries require separate parts to be molded and assembled, leading to time-consuming and costly processes, as well as visible seams that are aesthetically unappealing and weaken the diffuser.
Innovation Solution
A monolithic diffuser formed through additive manufacturing, such as 3D printing, which eliminates joints and seams by creating a single-piece component that can be coupled to an upper housing with tool-less connections, allowing for complex geometries and improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate parts are molded and assembled to form a diffuser with complex geometries, then the diffuser can be manufactured using conventional molding methods, but the process becomes time-consuming, costly, and results in visible seams that weaken the structure
Solution Approach 1:
The patent merges multiple separately molded parts into a single monolithic diffuser component manufactured through additive manufacturing. This eliminates the need for separate molding and assembly operations, directly resolving the contradiction by simplifying the manufacturing process while reducing time consumption.
Solution Approach 2:
The patent replaces conventional mechanical molding and assembly systems with additive manufacturing technology. This substitution enables the creation of complex geometries in a single continuous process, eliminating multiple molding cycles and assembly steps, thereby reducing both process complexity and manufacturing time.
2Ease of manufacture
If separate parts are assembled to form a diffuser, then conventional molding methods can be used, but visible seams appear at joints that are aesthetically unappealing and create weak points
Solution Approach 1:
The patent combines multiple separate parts into a single monolithic structure manufactured through additive manufacturing. This merging eliminates the joints and seams that would otherwise be present at interfaces between separately molded components, directly improving surface quality and eliminating aesthetic defects.
Solution Approach 2:
The patent changes the manufacturing approach from conventional subtractive/molding methods to additive manufacturing. This parameter change in the manufacturing process enables the creation of complex geometries with continuous, seamless surfaces, thereby improving manufacturing precision and surface quality.
3Ease of manufacture
If multiple separate parts are connected to form a diffuser, then conventional manufacturing can proceed, but the joints create weak points that reduce overall diffuser strength
Solution Approach 1:
The patent merges multiple separate parts into a single monolithic diffuser manufactured through additive manufacturing. This eliminates the joints and connections between separate components, removing the weak points that would compromise structural integrity, while maintaining manufacturing feasibility through advanced additive processes.
Solution Approach 2:
The patent replaces mechanical assembly methods (joining separate parts through fasteners, adhesives, or other connection mechanisms) with additive manufacturing. This substitution creates a continuous, monolithic structure without joints, thereby eliminating weak points and improving overall diffuser strength.
4Adaptability or versatility
If additive manufacturing is used to create a monolithic diffuser, then complex geometries can be achieved with improved structural integrity, but new manufacturing technology is required
Solution Approach 1:
The patent replaces conventional molding and assembly systems with additive manufacturing technology. This substitution enables the creation of complex geometries that would be impossible or extremely difficult to achieve with traditional methods, while the additive manufacturing process itself provides the necessary adaptability and versatility.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from conventional molding to additive manufacturing. This parameter change enables the creation of monolithic structures with complex internal and external geometries, improving design versatility and adaptability while the additive process handles the manufacturing complexity.
Data Source
AI summary
A lighting system includes an upper housing supporting a light engine, and a diffuser coupled to the upper housing. The diffuser may be monolithic, i.e. formed of a single material as a single piece without joints or seams where separate components are joined. The monolithic diffuser may be formed by an additive manufacturing process, for example 3D printing. The diffuser may couple to the upper housing with a tool-less connection. The portion of the tool-less connection defined by the diffuser may be formed by the additive manufacturing process. The lighting system may further include a lens coupled to the diffuser opposite the upper housing with a lens retaining ring. The lens retaining ring may be formed with an additive manufacturing process, and may define an annular snap-fit with the diffuser.