Flexible Lens Plate for Different LED Board Pitches
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Solution Overview
Problem
Existing lens plates for LED devices require new manufacturing tools for each change in LED pitch, leading to increased costs and complexity due to inflexible lens designs.
Innovation Solution
A lens plate with flexible connections between lens elements, allowing it to accommodate different LED pitches and shapes by stretching or squeezing, made from the same material as the lens elements, simplifying construction and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid lens plates are used with fixed lens element positions, then manufacturing precision for specific LED pitches is maintained, but adaptability to different LED pitches is lost
Solution Approach 1:
The lens plate employs flexible connections between lens elements that allow dynamic adjustment of lens element positions. The flexible connections can be stretched or compressed to accommodate different LED pitches while maintaining optical alignment, transforming the rigid fixed structure into a dynamic adjustable system.
Solution Approach 2:
The invention changes the physical state of the connections from rigid to flexible, allowing the lens plate to adapt its geometry. By using flexible connections made of elastic material, the lens plate can change its shape and dimensions to match different LED board configurations without compromising optical precision.
2Manufacturing precision
If separate manufacturing tools are created for each LED pitch, then manufacturing precision for each configuration is ensured, but device complexity and manufacturing cost increase
Solution Approach 1:
The lens plate is designed as a universal component that can serve multiple LED board configurations through its flexible connections. A single lens plate design can accommodate various LED pitches and board shapes, eliminating the need for separate manufacturing tools for each configuration while maintaining positioning accuracy.
Solution Approach 2:
The flexible connections allow the lens plate to change its geometric parameters (spacing, shape) to match different LED board configurations. This parameter adaptability enables one lens plate design to replace multiple specialized tools, reducing device complexity and manufacturing costs.
3Adaptability or versatility
If flexible connections are made from different material than lens elements, then flexibility is achieved, but construction complexity increases
Solution Approach 1:
The flexible connections are made from the same material as the lens elements, creating a homogeneous structure. This homogeneity simplifies construction and manufacturing while the flexible geometry of the connections (such as V-shaped or spring-shaped structures) provides the necessary flexibility for adaptation.
Solution Approach 2:
The flexible connections utilize thin, flexible geometric structures (V-shaped members, spring members) that can be molded from the same material as the lens elements. These flexible geometric forms provide the necessary adaptability while maintaining material uniformity, avoiding the complexity of multi-material construction.
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 flexible connections enable the lens plate to fit various LED boards with different pitches and shapes, maintaining optical accuracy and stability, thus reducing manufacturing costs and simplifying production.
Implementation Method 1
The flexible connection is formed out of a material richer in elasticity than a material forming the lenses
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
The present invention relates to a lens plate (10) for an LED device (100), comprising: a plurality of lens elements (12a-e); and a flexible connection (24a-d) between two lens elements of the plurality of lens elements so that at least one of a distance (P11) and an angle between the two lens elements can be adjusted, wherein the two lens elements and the flexible connection are made of the same material.