Solderable Reflector Holder for LED Lamp Alignment
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Solution Overview
Problem
The exact positioning and alignment of reflector units relative to the printed circuit board in luminaires are challenging due to the difficulty in attaching materials like coated hard plastics or light metals, which often require multiple assembly steps and can impair the optical function of the reflector unit.
Innovation Solution
A solderable reflector holder is attached to the reflector unit, allowing it to be positioned close to or directly on the printed circuit board, with the holder being molded or formed integrally with the reflector body during manufacturing, enabling precise alignment and a single joint soldering step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If reflector units are made from coated hard plastics or light metals, then optical function is improved, but attachment difficulty increases
Solution Approach 1:
A reflector holder made of solderable material (e.g., metal) is introduced as an intermediary component between the reflector unit (made of coated hard plastic or light metal) and the printed circuit board. The reflector holder can be soldered to the PCB, providing a reliable mechanical and electrical connection without requiring direct attachment of the difficult-to-attach reflector unit materials to the PCB.
2Reliability
If reflector holders grip reflector units in a form-fitting manner, then attachment reliability is improved, but alignment precision deteriorates
Solution Approach 1:
The reflector holder is designed with a form-fitting connection that allows the reflector unit to self-align during assembly. The holder's geometry provides guiding features that automatically position the reflector unit correctly relative to the printed circuit board, eliminating the need for complex external alignment mechanisms while maintaining both attachment reliability and alignment precision.
3Manufacturing precision
If multiple assembly steps are used for attaching reflector units, then positioning accuracy is improved, but production time increases
Solution Approach 1:
The reflector holder integrates multiple functions into a single component: it provides mechanical support, electrical connection (via soldering), and alignment guidance. By combining these functions into one element, the number of separate assembly steps is reduced while maintaining positioning accuracy, thereby improving productivity without sacrificing manufacturing precision.
4Ease of manufacture
If reflector holder material differs from reflector unit material, then solderability is improved, but material compatibility worsens
Solution Approach 1:
The reflector holder is constructed as a composite structure or uses a multi-material design that combines a solderable base material (such as metal) with surface treatments or coatings that provide compatibility with the reflector unit material. This allows the holder to be easily soldered to the PCB while also providing a compatible interface for attaching the reflector unit, whether made of coated hard plastic or light metal.
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
This method achieves precise alignment and positioning of the reflector unit while reducing assembly steps and minimizing optical obstruction, allowing for efficient light distribution and shortening production times.
Implementation Method 1
it is proposed to solder the reflector unit to the printed circuit board
Implementation Method 2
reflector units that sit above the light sources or encompass them and are accordingly arranged on or in front of the circuit board mentioned
Data Source
Figure 1
Figure 2(a)~2(c)
Figure 3
AI summary
The lamp (1) has a circuit board (2) on which a light source (3) i.e. LED, is arranged. A reflector unit (4) is attached to a reflector body (5) by a reflector holder (7). The circuit board is fastened to a retaining portion (9) of the reflector holder. The reflector holder is made of metallic material or plastic and provided with a soldering portion (8). The retaining portion is placed outside the reflector body. An aperture (6) surrounds a front end portion of the reflector body. The reflector holder is segmented into multiple separate reflector holder parts. An independent claim is also included for a method for manufacturing a lamp.