Method of LED light engine assembly
AssigneeLumileds LLC
InventorsFrederic Stephane Diana, Seng-Hup Teoh, Michael Wasilko
Life of this patent
Estimating the term…
Abstract
A lighting engine, system and method of fabrication are described. The system contains a flexible printed circuit (FPC) shaped as a loop. LEDs are mounted on the FPC to emit light toward a center of the loop. A light guide positioned in an interior of the loop receives light emitted by the LEDs through an edge of the light guide. The light guide has slots formed therein that receive locator pins to limit thermal displacement of the light guide towards the LEDs. Other apparatuses, systems, and methods are also disclosed.
Claims26
A method of assembling a lighting system, the method comprising:
- determining whether a chassis has mechanical defects outside of a predetermined nominal range of defect;
- removing residue on the chassis in response to determining that the reflector has no mechanical defects outside of the predetermined nominal range of defect;
- installing a gasket in a groove of the chassis after determining whether the chassis has mechanical defects outside of the predetermined nominal range of defect;
- mounting light emitting diode (LED) strips on the chassis to form a first integrated chassis;
- inserting locator pins into the chassis between LEDs of the LED strips;
- aligning a light guide plate (LGP) with the locator pins in the chassis;
- and
- placing the LGP aligned in the chassis such that the LGP in the chassis is retained by the locator pins to limit thermal displacement of the LGP towards the LEDs.
A method of assembling a lighting system, the method comprising:
- integrating light emitting diode (LED) strips on a flexible printed circuit board (FPC) with a chassis to form a first integrated chassis;
- inserting a light guide plate (LGP) into the first integrated chassis;
- illuminating the LED strips to determine whether at least one of optical and mechanical defects are present in a first surface of the LGP;
- determining whether optical and mechanical defects outside of a predetermined nominal range of defect are present in the first surface of the LGP;
- based on a determination that neither optical nor mechanical defects outside of the predetermined nominal range of defects are determined to be present in the first surface of the LGP, installing a reflector on the first surface of the LGP to form a second integrated chassis, the reflector installed to reflect light emitted by the LEDs into the LGP toward a second surface of the LGP opposing the first surface of the LGP;
- and
- determining whether Moiré fringes are present in the second surface of the LGP by varying a position of the second integrated chassis.
A method of assembling a lighting system, the method comprising:
- inserting locator pins into pin holes in a bottom of a cavity in a chassis such that the locator pins are disposed between light emitting diodes (LEDs) in LED strips attached to a sidewall of the cavity;
- aligning a light guide plate (LGP) with the locator pins and inserting the aligned LGP into the first integrated chassis and inserting the LGP into the chassis, the LGP retained by the locator pins;
- and
- illuminating the LED strips to determine whether at least one of mechanical and optical defects outside of a predetermined nominal range of defect are present in a first surface of the LGP.
A method of assembling a lighting system, the method comprising:
- mounting light emitting diode (LED) strips on a chassis to form a first integrated chassis;
- inserting locator pins into the chassis between LEDs of the LED strips;
- aligning a light guide plate (LGP) with the locator pins in the chassis;
- placing the LGP aligned in the chassis such that the LGP in the chassis is retained by the locator pins to limit thermal displacement of the LGP towards the LEDs;
- integrating a reflector in the chassis containing the LGP to form a second integrated chassis, the reflector integrated in the second integrated chassis to cover the LGP substantially entirely and reflect light emitted by the LEDs into the LGP toward an exit surface of the LGP;
- installing a strain relief mechanism to an outer portion of the second integrated chassis;
- and
- applying a protective film to the exit surface of the LGP in the second integrated chassis.
Dependencies are inferred from the claim text.