Reflector With Integral Spring Element For Tolerance Compensation
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Solution Overview
Problem
Existing reflectors for LED lamps require mechanical tolerances compensation, typically achieved using separate compensating elements like compression springs, which can lead to mispositioning and increased costs.
Innovation Solution
A reflector design with integral spring elements that provide accurate tolerance compensation, eliminating the need for separate springs and allowing for a compact, cost-effective manufacturing process by integrating the spring elements into the reflector itself, which can be made of metal or plastic with reflective surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate compensating elements like compression springs are used to compensate for mechanical tolerances, then tolerance compensation is achieved, but device complexity increases and mispositioning may occur
Solution Approach 1:
The spring element is integrated directly into the reflector body, merging the compensating element with the functional component. This eliminates the need for separate compensating elements and their associated mounting structures, thereby reducing device complexity while maintaining tolerance compensation capability
Solution Approach 2:
The reflector with integrated spring element compensates for its own manufacturing tolerances without requiring external compensating mechanisms. The spring element is part of the reflector itself, enabling self-service tolerance compensation and eliminating mispositioning issues associated with separate elements
2Manufacturing precision
If separate spring elements are used for tolerance compensation, then mechanical tolerances can be compensated, but manufacturing costs increase
Solution Approach 1:
By combining the spring element and reflector into a single integrated component, the manufacturing process is simplified. Instead of manufacturing separate spring elements and reflectors and then assembling them, the integrated design allows for single-step manufacturing or pre-assembly, reducing labor and assembly costs
Solution Approach 2:
The integrated spring-reflector component serves multiple functions simultaneously: it provides the reflective surface for light redirection, acts as a mechanical spring for tolerance compensation, and serves as a structural mounting element. This multi-functionality reduces the total number of components and manufacturing steps
3Manufacturing precision
If separate spring elements are used, then tolerance compensation is possible, but compact design is limited due to mispositioning issues
Solution Approach 1:
The integration of the spring element into the reflector body eliminates the need for additional space required for separate mounting structures and alignment features. The compact spring-reflector unit can be directly mounted without requiring separate positioning mechanisms, enabling more compact overall device design
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 reflector achieves precise tolerance compensation, reduces manufacturing costs, and allows for a compact design by using integral spring elements to apply contact pressure, thereby eliminating mispositioning and enabling accurate beam guidance.
Implementation Method 1
The at least one spring element enables contact pressure to be applied to the reflector for highly accurate tolerance compensation
Implementation Method 2
A reflector can be understood in particular as meaning a generally beam-shaping element which can be implemented in particular as a specularly reflecting element or as a diffusely reflecting element
Data Source
AI summary
A reflector (1; 31; 41) for a lighting device comprising: (13; 61; 62), at least one rear cutout (6) for a light source (20; 47; 56) in each case and at least one front-side reflector opening (8), wherein at least one spring element (10; 34; 45) is incorporated into the reflector (1; 31; 41).