Spring Element Lighting Device Mounting
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Solution Overview
Problem
Existing lighting devices for automotive applications face challenges in reliably and precisely mounting light-emitting modules due to misalignment issues caused by torque variations and thermal expansion, particularly in high-heat environments, where conventional fixing methods like screws or rivets are inadequate.
Innovation Solution
A lighting device utilizing a spring element with multiple spring sections that exert forces in different spatial directions to securely position and align the light-emitting module relative to the optical system, providing thermal stability and eliminating the need for conventional fixing means like screws or rivets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a threaded connection (screws or nuts) is used to fix the light-emitting module, then the module can be securely mounted to the optical system, but the positioning precision deteriorates due to torque variations causing misalignment
Solution Approach 1:
The patent changes the fixing mechanism from rigid threaded connection to elastic spring-based clamping. The spring element deforms elastically to provide clamping force, transforming the fixing approach from torque-dependent rigid fastening to elasticity-based adaptive clamping that maintains constant contact pressure without requiring precise torque control
Solution Approach 2:
The patent replaces the mechanical threaded connection system with a spring-based clamping system. Instead of using screws that require torque application and precise threading, the invention uses spring elements that naturally provide clamping force through elastic deformation, eliminating the need for torque-controlled fastening operations
2Strength
If a threaded connection is used to fix the light-emitting module, then the module can be securely mounted, but the positioning stability deteriorates due to thermal expansion causing temperature-dependent displacement
Solution Approach 1:
The patent introduces dynamic adaptability through spring elements that can continuously adjust their clamping force in response to thermal expansion. Unlike rigid threaded connections that create stress and displacement when components expand, the spring-based system dynamically accommodates dimensional changes while maintaining secure clamping, preventing misalignment during temperature variations
Solution Approach 2:
The patent explicitly addresses thermal expansion by using spring elements that accommodate the dimensional changes of components under temperature variations. The elastic spring structure allows for controlled deformation that absorbs thermal expansion effects, preventing the stress and misalignment that would occur with rigid fixed-point mounting
3Strength
If conventional fixing means (screws or rivets) are used, then the light-emitting module can be mounted, but the device complexity increases due to the need for additional fixing mechanisms and precise positioning features
Solution Approach 1:
The patent merges the functions of positioning and fixing into a single spring element. Instead of requiring separate positioning features (such as precision holes or slots) and separate fixing elements (screws or rivets), the spring-based clamping mechanism performs both positioning and securing functions simultaneously, reducing the number of components and simplifying the overall mounting structure
Solution Approach 2:
The spring element serves multiple functions: it provides clamping force for secure mounting, enables precise positioning through elastic deformation, and accommodates thermal expansion. This multi-functional design eliminates the need for specialized positioning features and separate fixing mechanisms, reducing device complexity while maintaining mounting security
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 solution ensures precise and reliable positioning of the light-emitting module along multiple spatial directions, minimizing thermal-induced displacement and distortion, and simplifies the mounting process by eliminating the need for additional fixing mechanisms.
Implementation Method 1
at least one spring element for fixing the light-emitting module to the optical system in a clamping position, wherein the at least one spring element comprises a first spring section configured to exert a spring force in a first spatial direction towards the first reference face
Implementation Method 2
The thermal expansion of a light-emitting module that is fixed on one or more points by means of a threaded connection may lead to a temperature-dependent displacement and/or distortion of the light-emitting module relative to these fixed points
Data Source
AI summary
The invention refers to a lighting device (18) comprising a light-emitting module (2) and an optical system. The optical system comprises a first reference face (16), wherein the first reference face (16) is configured to accommodate the light-emitting module (2); and at least one spring element (20) is provided for fixing the light-emitting module (2) to the optical system in a clamping position, wherein the at least one spring element (20) comprises a first spring section (26) configured to exert a spring force in a first spatial direction (f1) towards the first reference face (16) in the clamping position, wherein the at least one spring element further comprises a second spring section (28) configured to exert a spring force towards a second spatial direction (f2) in the clamping position, and wherein the second spatial direction (f2) is different from the first spatial direction (f1). The invention further relates to a method for fixing a light-emitting module (2) to an optical system.