Optical Plate Electrical Integration for Shock-Resistant Lighting Units
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Solution Overview
Problem
Existing lighting units face issues with unreliable electrical connections due to heterogeneous material assemblies prone to cracks and failures from physical shocks and vibrations, and challenges in sealing power cabling, especially in harsh environments.
Innovation Solution
An optical plate with integrated electrical connecting elements that provide convenient and reliable electrical connections through alignment guides and seals, ensuring secure power and data transmission while maintaining environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are soldered to the integrated circuit for electrical connection, then electrical contact is achieved, but the heterogeneous material assembly becomes prone to cracks and failures from physical shocks and vibrations
Solution Approach 1:
The patent integrates the electrical connecting element directly into the optical plate, merging the optical component and electrical connection function into a single unified structure. This eliminates the separate wire soldering process and heterogeneous material assembly, resolving the contradiction by creating a homogeneous integration that resists physical shocks and vibrations while maintaining reliable electrical contact.
Solution Approach 2:
The optical plate serves multiple functions: it provides optical guidance for light sources and simultaneously integrates electrical connecting elements for power and data transmission. This multi-functionality eliminates the need for separate cabling components, improving both reliability and structural stability by reducing the number of interfaces and material joints.
2Ease of operation
If flexible wires are used for input cabling, then electrical connection flexibility is improved, but sealing against dust and water ingress becomes challenging
Solution Approach 1:
By integrating the electrical connecting element directly into the rigid optical plate structure, the patent eliminates the need for flexible wires. The electrical connection is achieved through the rigid plate itself, which can be sealed effectively against dust and water ingress while maintaining the necessary electrical conductivity and connection flexibility through design.
3Reliability
If through-holes with grommets and soldering are used for wire passage, then electrical connection is achieved, but the process becomes cumbersome requiring multiple manipulations
Solution Approach 1:
The patent combines the electrical connecting element with the optical plate into a single integrated component. This eliminates the separate steps of creating through-holes, installing grommets, and performing soldering operations. The integrated design allows for simpler manufacturing processes while maintaining reliable electrical connections.
4Manufacturing precision
If alignment guides are provided for predetermined positioning, then electrical connection precision is improved, but the device complexity increases
Solution Approach 1:
The alignment guides are integrated into the optical plate structure itself, serving dual purposes: they provide precise alignment for electrical connections and simultaneously function as part of the optical guidance system. This multi-functionality adds minimal complexity while achieving high manufacturing precision.
Data Source
AI summary
Example embodiments relate to optical plates with integrated connections. One example lighting unit includes a substrate. The lighting unit also includes one or more light sources provided to a top surface of the substrate. Additionally, the lighting unit includes at least one electrical contact provided to the top surface of the substrate. Further, the lighting unit includes an optical plate having an inner surface and an outer surface. The optical plate includes one or more optical elements. The one or more optical elements are configured for cooperating with the one or more light sources. The inner surface of the optical plate faces the top surface of the substrate. The optical plate further includes at least one electrical connecting element. The at least one electrical connecting element is configured for being connected electrically to the at least one electrical contact, and for providing electrical connection through the optical plate.