Patent Publication Number: US-2015062919-A1

Title: Optical lens positioning system and method

Description:
FIELD OF THE INVENTION 
     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. 
     BACKGROUND OF THE INVENTION 
     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. 
     SUMMARY OF THE INVENTION 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG. 1  is a top perspective view of one embodiment of an optical lens positioning system that includes a retaining mechanism and an optical lens; 
         FIG. 2  is a top perspective exploded view of the optical lens positioning system of  FIG. 1 ; 
         FIG. 3  is a top perspective view of one embodiment of an optical lens positioning system of  FIG. 1 , wherein the retaining mechanism is shown retaining the optical lens in a fixed position proximate an illumination source; 
         FIG. 4  is a bottom perspective view of the optical lens positioning system of  FIG. 3 ; and 
         FIG. 5  is a top view of the optical lens positioning system of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     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  FIG. 1 , reference numeral  10  generally designates an optical lens positioning system having a retaining mechanism  12  for retaining an optical lens  14  proximate an illumination source  15 . The retaining mechanism  12  includes a base  16  and at least one alignment member that is shown in one embodiment having eight alignment members  18   a - 18   h  coupled to the base  16  and extending therefrom. The alignment members  18   a - 18   h  are coupled to the periphery of the optical lens  14 , which may be a stand alone or housed in a lens holder  20 . While eight alignment members  18   a - 18   h  are shown and described herein, it should be appreciated that other numbers, shapes, and/or sizes of alignment members may be employed according to other embodiments. 
     Referring to  FIG. 2 , one embodiment of the optical lens  14  and the lens holder  20  is shown. In the illustrated embodiment, the lens holder  20  includes a first section  22  configured to be stacked on top of a second section  24  for holding the optical lens  14  therebetween. The first section  22  includes an aperture  26   a,  a pair of oppositely disposed tabs  28   a,    28   b,  and a pair of oppositely disposed flanges  30   a,    30   b.  Similarly, the second section includes an aperture  26   b,  a pair of oppositely disposed tabs  28   c,    28   d,  and a pair of oppositely disposed flanges  30   c,    30   d.  In the illustrated embodiment, aperture  26   a  is aligned with aperture  26   b,  tabs  28   a  and  28   b  are aligned with tabs  28   c  and  28   d,  respectively, and flanges  30   a  and  30   b  are aligned with flanges  30   c  and  30   d,  respectively. 
     The optical lens  14  includes projections  32   a - 32   d,  wherein projection  32   a  is formed opposite to projection  32   b  and projection  32   c  is formed opposite to projection  32   d.  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  26   a  receives projection  32   a  and aperture  26   b  receives projection  32   b.  In this arrangement, tabs  28   a  and  28   c  abut against projection  32   c  and tabs  28   b  and  28   d  abut against projection  32   d.  To prevent disassembly of the lens holder  20 , flange  30   a  is adapted for connection with flange  30   c  and flange  30   b  is adapted for connection with flange  30   d  via mechanical fasteners  34   a  and  34   b.  In addition, or alternatively, adhesives and/or other suitable bonding methods may be used for connecting flanges  30   a  and  30   b  to  30   c  and  30   d,  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  FIG. 2 , one embodiment of the retaining mechanism  12  is shown. In the illustrated embodiment, the base  16  of the retaining mechanism  12  is planar and includes an intermediate portion  36  connecting a first and second linear portion  38 ,  40  to form a space  42  therebetween. The alignment members  18   a - 18   h  are coupled to the periphery of the base  16  and are configured to be displaceable to enable the optical lens  14  to be retained in a variety of positions. When not retaining the optical lens  14 , it is contemplated that the alignment members  18   a - 18   h  may be disposed orthogonally or angled relative to the base  16 . The alignment members  18   a - 18   h  each include a distal connecting portion  44  and a bipedal portion  46 , which are shown on alignment member  18   a.  The bipedal portion  46  is coupled to the base  16  and widens as it extends from the connecting portion  44  towards the base  16 . In addition, it is contemplated that the connecting portion  44  and bipedal portion  46  may each have linear and/or non-linear configurations and may be coplanar and/or nonplanar with respect to one another. 
     In the illustrated embodiment, the alignment members  18   a - 18   h  are cantilevered to the base  16  and are constructed from a flexible material (i.e. metal or plastic) such that alignment members  18   a,    18   b,    18   e,  and  18   f  are each displaceable in a corresponding first plane and alignment members  18   c,    18   d,    18   g,  and  18   h  are each displaceable in a corresponding second plane, wherein displacement of alignment members  18   a - 18   h  occurs via a flexing motion. With respect to the illustrated embodiment as oriented in  FIG. 2 , the first plane includes horizontal (i.e. sideways) flexing of corresponding alignment members  18   a,    18   b,    18   e,  and  18   f  relative to the base  16  and the second plane includes vertical (i.e. upwards/downwards) flexing of corresponding alignment members  18   c,    18   d,    18   g,  and  18   h  relative to the base  16 . In this configuration, the first plane corresponding to alignment members  18   a,    18   b,    18   e,  and/or  18   f  is nonplanar with the second plane corresponding to alignment members  18   c,    18   d,    18   g,  and/or  18   h . More specifically, and with respect to the illustrated embodiment, the first plane corresponding to alignment members  18   a,    18   b,    18   e,  and/or  18   f  is orthogonal to the second plane corresponding to alignment members  18   c,    18   d,    18   g,  and/or  18   h.  Furthermore, due to the coupling of alignment members  18   a - 18   h  to the base  16 , the alignment members  18   a - 18   h  will tend to resist being displaced in a plane that is orthogonal to their corresponding planes. With respect to the illustrated embodiment as oriented in  FIG. 2 , alignment members  18   a,    18   b,    18   e,  and  18   f  will exert stiffness towards being flexed in a vertical direction relative to the base  16  while alignment members  18   c,    18   d,    18   g,  and  18   h  will exert stiffness towards being flexed in a horizontal direction relative to the base  16 . While the alignment members  18   a - 18   h  have been described herein to be displaceable via a flexing motion, those having ordinary skill in the art will recognize other means in which to adjust the position of the alignment members  18   a - 18   h.  For instance, it is contemplated that the alignment members  18   a - 18   h  may be hinged to the base  16  such that displacement may also occur via a swinging motion, in addition to, or independent of, the above described flexing motion. 
     As further shown in  FIG. 2 , the retaining mechanism  12  may be coupled to a carrier  48 , which includes a carrier associated with any of the aforementioned automobile lighting systems. In the illustrated embodiment, the retaining mechanism  12  is secured to the carrier  48  via mechanical fasteners  50 . Additionally, or alternatively, the retaining mechanism  12  may be secured to the carrier  48  via adhesive, welding, or other suitable bonding methods. Further, the retaining mechanism  12  is operably coupled to the illumination source  15 , which is disposed in the space  42  of the retaining mechanism  12 . The illumination source  15  may include one or more light emitting diodes (LEDs) or other types of lighting. In the illustrated embodiment, the illumination source  15  is exemplarily shown as an array of light emitting diodes (LEDs), which may be directly connected to the carrier  48 , or an intermediate substrate  52  such as a printed circuit board (PCB), heat sink, or other surface having heat dissipating properties. Alternatively, the base  16  of the retaining mechanism  12  can be constructed from metal and without space  42 , thereby providing heat dissipation and enabling the illumination source  15  to be directly mounted thereto. 
     Referring to  FIGS. 3-5 , the retaining mechanism  12  and optical lens  14  of the previous embodiment are shown, wherein the retaining mechanism  12  is coupled to the carrier  48  and retains the optical lens  14  proximate to the illumination source  15 . While, the optical lens  14  can be retained in a variety of positions, it is often desirable to retain the optical lens  14  in a position that optimizes light output therefrom, which typically occurs when the focal point of the optical lens  14  is aligned with the illumination source  15 . In previous systems, attempts at positioning an optical lens relative to an illumination source often led to tolerance stack up, thus impacting the precision and efficiency of the beam pattern being emitted from the optical lens. These concerns can be substantially minimized through the adoption of the optical lens positioning system  10  described herein. As such, an optical lens positioning method adapted for use with the optical lens positioning system  10  is described below. 
     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  18   a - 18   h.  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  18   a - 18   h.  Thus, as the lens holder  20  clears the entry point, the connecting portion  44  of each alignment member  18   a - 18   h  abuts against the lens holder  20  and the alignment members  18   a - 18   h  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  18   a - 18   h  to exert a force against the lens holder  20  since the alignment members  18   a - 18   h  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  18   a - 18   h  to abut against a larger perimeter portion of the lens holder  20 . As a result, the alignment members  18   a - 18   h  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  18   a - 18   h  to abut against a smaller perimeter portion of the lens holder  20 . As a result, the alignment members  18   a - 18   h  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  FIG. 3 , may also be adjusted via sideways movement, upwards or downwards movement, horizontal rotation, and/or vertical rotation. In each of these cases, the alignment members  18   a - 18   h  will flex according to their planes of displacement in either an inward or outward direction relative to the base  16  in response to positional and/or rotational shifting of the optical lens  14 . In this manner, the optical lens  14  can be easily positioned to obtain optimal light output, or other levels of light output, by simply observing the light output from the optical lens  14  while one or more of the aforementioned adjustments are being made. Thus, in view of the above-mentioned ways for adjusting the position of the optical lens  14 , it should be evident that the retaining mechanism  12  of the illustrated embodiment is able to support movement of the optical lens  14  in up to three planes and rotation of the optical lens  14  about a maximum of two axes. As a result, the optical lens  14  may be positioned relative to the illumination source  15  at numerous distances that produce varying levels of light output from the optical lens  14 . In addition, the optical lens  14  can be positioned orthogonally or at an angle with respect to the base  16  to enable light being outputted from the optical lens  14  to be aimed in a variety of directions. 
     Once the optical lens  14  is located in a desired position, the connecting portion  44  of each alignment member  18   a - 18   h  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  18   a - 18   h  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.