Optic Frame Cell Structure for Thermal Alignment Stability
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Solution Overview
Problem
Light modules with arrayed optics experience misalignment due to thermal expansion of materials like silicone, leading to inefficiencies in light distribution.
Innovation Solution
A frame is used to retain discrete optics over LEDs, featuring a design with frame cells that accommodate and secure optics, utilizing materials with low thermal expansion to maintain alignment and stability under heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicone material is used to form the lens, then the lens can be formed with desired optical properties, but the lens expands due to thermal expansion when exposed to heat generated by LEDs, resulting in misalignment between LEDs and optic
Solution Approach 1:
The patent changes the material parameter of the lens from silicone (high thermal expansion coefficient) to optical-grade plastic or glass (low thermal expansion coefficient). This parameter change reduces thermal expansion when exposed to LED heat, thereby maintaining optical alignment between LEDs and lens while still allowing the lens to fulfill its optical function.
2Manufacturing precision
If a frame is introduced to retain discrete optics, then optical alignment and stability are improved, but device complexity increases
Solution Approach 1:
The frame structure serves multiple functions simultaneously: it retains discrete optics in proper position, compensates for thermal expansion of silicone lenses, provides mechanical support for the entire optical array, and enables customizable light distribution through its cell design. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving improved optical alignment and stability.
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 frame maintains optical alignment and enhances light module performance by preventing thermal expansion, allowing for customizable light distribution and improved lumen output.
Implementation Method 1
Some materials used to form the lens (e.g., silicone) have a relatively high coefficient of thermal expansion such that they are apt to expand in size when exposed to the heat generated by the LEDs. Such expansion can result in misalignment between the LEDs and their respective optic on the lens.
Data Source
AI summary
Embodiments are directed to an optic frame for discrete optics, light modules with such frames, and methods of assembling such light modules such that each discrete optics resides in a cell of the optic frame. The optic frame is designed to prevent or reduce the blockage of light from the light module and to isolate discrete optics from neighboring discrete optics such that the performance of one optic (e.g., thermal expansion) does not negatively impact the performance of neighboring optics.