Discrete Optics Light Modules with Direct PCB Sealing

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Solution Overview

Problem

Existing light modules with arrayed optics have a multi-part, complex construction that increases material costs, assembly time, and risk of product failure, necessitating a more efficient method to attach optics directly to a printed circuit board.

Innovation Solution

The use of discrete optics, which are directly attached and sealed to a printed circuit board without the need for gaskets or frames, allowing for customizable light module designs with independent rotational orientations and varied optical geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional multi-part construction with gaskets and frames is used, then sealing and protection are achieved, but device complexity and assembly time increase

Engineering Contradiction:

Improvesealing and protectionVSAvoidnumber of component parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the lens, gasket, and frame into a single integrated optic assembly. The lens is formed with integrated sealing features that eliminate the need for separate gaskets and frames, reducing the number of component parts while maintaining sealing and protection functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated optic structure performs multiple functions simultaneously - it provides optical focusing, sealing against moisture and particulates, and mechanical support. This multi-functionality eliminates the need for separate dedicated components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional multi-part construction is used, then sealing is provided, but assembly time and material costs increase

Engineering Contradiction:

Improveprotection against moisture and particulatesVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

By combining multiple components into a single integrated optic assembly, the number of assembly steps is dramatically reduced. The lens is pre-formed with sealing features, eliminating the need to assemble separate gaskets and frames, thus reducing assembly time while maintaining protection against moisture and particulates.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If discrete optics are attached directly to PCB, then component parts are reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvenumber of component partsVSAvoidalignment precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The lens is pre-formed with integrated alignment features and sealing structures before being attached to the PCB. This preliminary formation of the complete optic assembly with precise geometries reduces the precision requirements during the final assembly process, as the components are pre-configured to align correctly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12439522B2Light module with discrete optics and methods of assembling same

Publication Date: 2025.10.07 ABL IP HLDG LLC

AI summary

Embodiments are directed to optics, light modules with such optics, and methods of assembling such light modules such that the optics are attached and sealed directly to a printed circuit board, thereby eliminating the need for gaskets and a frame and reducing the number of component parts of the light module. In some embodiments, the optics are discrete optics that can each be attached to the printed circuit board independent of the other optics.