Patent Application
20150062919
The present invention generally relates to illumination systems, and more specifically to illumination systems in which an optical lens is positioned relative to an illumination source.
Illumination systems are used in a variety of applications. One shortcoming arising in current illumination systems includes the occurrence of tolerance stack up when an optical lens is positioned relative to an illumination source in order to collect and project light. As a result of tolerance stack up, the efficiency and precision of the illumination system may be adversely affected, which generally manifests itself as less than optimal light output from the optical lens. Thus, there is a need for an optical lens positioning system having minimal tolerance stack up and optimal light output capabilities.
According to one aspect of the present invention, an optical lens positioning system is provided that includes an illumination source, an optical lens, and a retaining mechanism having a plurality of alignment members that are displaceable in a first plane and resist being displaced in a second plane that is orthogonal to the first plane, wherein the plurality of alignment members are coupled to the optical lens to retain the optical lens proximate to the illumination source.
According to another aspect of the present invention, an optical lens positioning system is provided and includes a retaining mechanism operably coupled to an illumination source and having a first and a second alignment member displaceable in nonplanar planes. An optical lens is disposed between the first and second alignment members, wherein the first and second alignment members are configured to retain the optical lens in a fixed position proximate the illumination source.
According to another aspect of the present invention, an optical lens positioning method is provided and includes the steps of providing a retaining mechanism having a plurality of alignment members, abutting the plurality of alignment members against a periphery of an optical lens, adjusting the position of the optical lens, which causes the plurality of alignment members to be displaced, and using the plurality of alignment members to retain the optical lens in a fixed position proximate an illumination source.
These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.
In the drawings:
As required, detailed embodiments of the present invention are disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to a detailed design and some schematics may be exaggerated or minimized to show function overview. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
Referring to
Referring to
The optical lens 14 includes projections 32a-32d, wherein projection 32a is formed opposite to projection 32b and projection 32c is formed opposite to projection 32d. To assemble the optical lens 14 inside the lens holder 20, the optical lens 14 is sandwiched between the first and second sections 22, 24 such that aperture 26a receives projection 32a and aperture 26b receives projection 32b. In this arrangement, tabs 28a and 28c abut against projection 32c and tabs 28b and 28d abut against projection 32d. To prevent disassembly of the lens holder 20, flange 30a is adapted for connection with flange 30c and flange 30b is adapted for connection with flange 30d via mechanical fasteners 34a and 34b. In addition, or alternatively, adhesives and/or other suitable bonding methods may be used for connecting flanges 30a and 30b to 30c and 30d, respectively.
The optical lens 14 may be a variety of lens types and take on a variety of configurations.
As such, the lens holder 20 may be constructed in a variety of shapes to accommodate different optical lens configurations. For instance, the lens holder 20 may contour the optical lens 14 or may be of a different shape than the optical lens 14. In the illustrated embodiment, the lens holder 20 has a tapered configuration and the optical lens 14 includes a collimating lens, which focuses collected light as a light beam and may be used in various automotive lighting assemblies such as, but not limited to, head lamps, fog lamps, backup lamps, supplemental lamps (i.e. trailer hitch lamps), daytime lamps, and/or turn signal lamps. Thus, one contemplated use of the optical lens positioning system 10 disclosed herein includes automotive lighting applications. However, it is to be understood that the optical lens positioning system 10 is also readily adaptable to other lighting applications without departing from the teachings provided herein.
Referring again to
In the illustrated embodiment, the alignment members 18a-18h are cantilevered to the base 16 and are constructed from a flexible material (i.e. metal or plastic) such that alignment members 18a, 18b, 18e, and 18f are each displaceable in a corresponding first plane and alignment members 18c, 18d, 18g, and 18h are each displaceable in a corresponding second plane, wherein displacement of alignment members 18a-18h occurs via a flexing motion. With respect to the illustrated embodiment as oriented in
As further shown in
Referring to
The optical lens positioning method includes placing the optical lens 14 in the retaining mechanism 12 such that the optical lens 14 is positioned between the alignment members 18a-18h. In the illustrated embodiment, the perimeter size of the lens holder 20 is configured to be larger than the entry point between the alignment members 18a-18h. Thus, as the lens holder 20 clears the entry point, the connecting portion 44 of each alignment member 18a-18h abuts against the lens holder 20 and the alignment members 18a-18h are flexed according to their respective planes of displacement in an outwards direction relative to the base 16 in order to accommodate the lens holder 20. This causes the alignment members 18a-18h to exert a force against the lens holder 20 since the alignment members 18a-18h have a natural disposition to return to their original positions when flexed in their respective planes of displacement.
When placed in the retaining mechanism 12, the position of the optical lens 14 can be adjusted by moving the optical lens 14 towards or away from the base 16 of the retaining mechanism 12. Due to the tapered configuration of the lens holder 20, when the optical lens 14 is moved towards the base 16, the shift in position causes the connecting portion 44 of each alignment member 18a-18h to abut against a larger perimeter portion of the lens holder 20. As a result, the alignment members 18a-18h will experience greater outward flex according to their respective planes of displacement in order to accommodate the lens holder 20. Conversely, when the optical lens 14 is moved away from the base 16, the shift in position causes the connecting portion 44 of each alignment member 18a-18h to abut against a smaller perimeter portion of the lens holder 20. As a result, the alignment members 18a-18h will naturally flex inwards relative to the base 16 toward their original position.
In addition to moving the optical lens 14 towards or away from the base 16, the position of the optical lens 14 within the retaining mechanism 12, as oriented in
Once the optical lens 14 is located in a desired position, the connecting portion 44 of each alignment member 18a-18h is fixedly coupled to the lens holder 20 so that the optical lens 14 is retained in a fixed position and is prevented from being further moved or rotated. In the illustrated embodiment, the connecting portions 44 are curved to increase surface area and welded to the lens holder 20 at weld points 54. Depending on the position and/or degree of rotation of the optical lens 14, the weld points 54 may be located on the connecting portions 44 at other positions. While the connecting portions 44 are shown welded to the lens holder 20, other bonding methods may be used additionally or alternatively, and include the use of adhesives and/or mechanical fasteners (e.g. bolts, screws, etc.). Furthermore, while the optical lens positioning method has been described in relation to the optical lens 14 and lens holder 20 ensemble, it is equally applicable to the optical lens 14 as a stand alone unit. For instance, in the event where no lens holder 20 is used, the optical lens 14 may be configured similarly to the lens holder 20 such that the alignment members 18a-18h abut directly against the optical lens 14 via their respective connecting portions 44 and flex accordingly, thus enabling the optical lens 14 to be positioned and rotated in the absence of the lens holder 20 in the manner previously described.
Accordingly, an optical lens positioning system and method has been advantageously provided herein, which enables an optical lens to be positioned proximate an illumination source and retained in a variety of positions. By employing the optical lens positioning system and method, the optical lens is easily positioned to obtain maximum optical performance, which minimizes tolerance stack up while increasing efficiency and precision for any given lumen budget.
For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.
It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
