Optic Positioning Device With Channel-Based Retention
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Solution Overview
Problem
Existing methods for associating optics with light sources, such as LEDs, are inefficient and often result in damage during installation or removal, as optics are typically affixed irreversibly, leading to challenges in directing and patterning light effectively in lighting fixtures.
Innovation Solution
A device with a channel-based design that securely holds optics in place using a base with an aperture and opposed sidewalls, preventing axial, lateral, and longitudinal movement, allowing for flexible insertion and removal without damage, and can be adapted for various light sources and patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optics are affixed irreversibly to the LED device or PCB, then the optics are securely held in place, but removal or adjustment of the optics results in breaking the legs or mounting elements
Solution Approach 1:
The mounting system is divided into separate components: a body portion with legs that mounts to the PCB, and an optic that can be independently installed and removed. The channel structure segments the retention function from the mounting function, allowing the optic to be secured without permanently attaching it to the PCB structure.
Solution Approach 2:
The channel acts as an intermediary structure between the optic and the mounting system. It provides a retaining mechanism that secures the optic during operation but allows for removal without damage to other components. The channel body serves as a mediator that decouples the optic from direct attachment to the PCB legs.
2Manufacturing precision
If optics are mounted one at a time, then each optic can be individually positioned, but the process is time-consuming and inefficient for multiple LEDs
Solution Approach 1:
Multiple channels are combined into a single integrated structure that can hold multiple optics simultaneously. The channels are formed as unified components with consistent geometric features, allowing multiple optics to be installed using the same positioning methodology while significantly reducing installation time compared to individual mounting operations.
Solution Approach 2:
The channel design provides universal features that work for all optics in the array. The geometric engagement features, aperture dimensions, and retention mechanisms are standardized across all channels, allowing a single installation process to be replicated for multiple optics without requiring custom positioning procedures for each individual optic.
3Reliability
If rigid mounting structures are used to secure optics, then the optics are firmly held, but the installation and removal process becomes difficult and potentially damaging
Solution Approach 1:
The channel incorporates flexible sidewalls that can dynamically adjust during installation and removal. The sidewalls are configured to flex outwardly to accommodate the optic during insertion, then return to a retained position to securely hold the optic during operation. This dynamic behavior allows easy installation and removal while maintaining firm retention when needed.
Solution Approach 2:
The channel sidewalls are designed as flexible structures that can deform elastically. This flexibility allows the mounting structure to accommodate the optic without requiring forceful installation or removal, reducing the risk of damage while maintaining secure retention. The thin-walled construction enables the necessary flexibility while preserving structural integrity for retention.
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 device provides a secure, flexible, and reversible method for positioning optics, enabling effective light distribution and pattern control while accommodating different light sources and patterns, enhancing the efficiency and durability of lighting systems.
Implementation Method 1
the optic includes a frustum-shaped lens for refracting light emitted from an associated LED into a predetermined pattern
Data Source
AI summary
A device for holding and positioning an optic, such as a refractive lens, over a light source such as a light emitting diode. The refractive lens is frustum-shaped with an upper light-exiting end having an upper rim, a lower light-entering end, and a conical sidewall that tapers from the upper rim to the lower end. The device has a channel including a base and first and second sidewalls extending from the opposed side edges of the base, and further having one or more optic holding positions. The optic holding position includes an aperture formed in the base that is configured to receive the conical sidewall of the optic, and an aperture formed in a portion of each sidewall, adjacent the aperture in the base, for retaining a portion of the upper rim of the optic lens. The aperture can include a slot opening through which a portion of the upper rim of the optic lens at least partially extends.