Insert-Molded LED Light Guide Assembly for Compact Lighting
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Solution Overview
Problem
Existing LED lighting devices require complex assembly processes, are large in size, and have low light transmission efficiency due to separate optical fibers and cover members, limiting design flexibility and increasing costs.
Innovation Solution
An LED lighting device with a transparent cover member and integrated light transmission member formed using insert molding, eliminating the need for separate optical fibers and providing a compact, waterproof design with enhanced light transmission efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate optical fiber and cover member structure is used, then the optical fiber can be attached to the LED element, but the assembly process becomes complex and requires additional glue fixation steps
Solution Approach 1:
The patent combines the cover member and light transmission member into a single integrated component. The cover member includes an integrated light transmission member with a light introducing end that directly contacts the LED element's light emitting surface, eliminating the need for separate optical fiber attachment and glue fixation steps.
Solution Approach 2:
The light transmission member is pre-formed as an integral part of the cover member during molding, with the light introducing end already positioned and shaped to directly receive light from the LED element. This preliminary formation eliminates the need for subsequent assembly steps to attach separate optical components.
2Adaptability or versatility
If a separate optical fiber and cover member structure is used, then the optical fiber can be fixed to the cover member, but the device size increases and mounting flexibility decreases
Solution Approach 1:
The cover member and light transmission member are merged into a single integrated component, reducing the overall device volume by eliminating the need for separate optical fiber and fixation structures. The integrated design allows for more compact mounting configurations.
Solution Approach 2:
The integrated cover member simultaneously serves as both a protective cover and a light transmission structure. The light transmission member is formed as an integral part of the cover member, allowing the same component to fulfill multiple functions and reduce overall device complexity and size.
3Productivity
If existing optical fiber is used with a fiber insertion hole, then the optical fiber can be attached to the cover member, but light taking-out efficiency decreases due to gap between LED and fiber
Solution Approach 1:
The patent eliminates the air gap between the LED element and the light transmission medium by having the light introducing end of the integrated light transmission member directly contact the light emitting surface of the LED element. This direct contact removes the inefficient air interface and improves light coupling.
Solution Approach 2:
The light transmission member is pre-positioned and integrated into the cover member structure during molding, with its light introducing end precisely formed to directly receive light from the LED element. This preliminary positioning ensures optimal light coupling efficiency from the start, eliminating the need for subsequent alignment and adjustment.
4Reliability
If a fiber insertion hole with glue fixation is used, then the optical fiber can be secured to the cover member, but the fixation becomes unreliable due to limited insertion depth
Solution Approach 1:
The cover member and light transmission member are merged into a single integrated component, eliminating the need for separate fixation mechanisms. The light transmission member is formed as an integral part of the cover member, providing inherent structural support and reliable light transmission without relying on glue fixation or deep insertion holes.
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 solution minimizes assembly steps, reduces size, enhances light transmission efficiency, and offers design flexibility while maintaining high optical and heat resistance characteristics, making it suitable for various applications including vehicle lighting.
Implementation Method 1
a light transmission member receiving emission light from the light emitting surface of the LED element at a light inlet end and operating as a light transmission path
Implementation Method 2
the light transmission member is integrated with the LED element mounted on the substrate together with the cover member using a transparent resin by insertion molding
Data Source
AI summary
An LED lighting device includes a transparent cover member arranged at an exterior member or an interior member and covering an LED element and a light emitting surface of the LED element mounted on a substrate, and a light transmission member receiving emission light from the light emitting surface of the LED element at a light inlet end and operating as a light transmission path. The light transmission member is integrated with the LED element mounted on the substrate together with the cover member using a transparent resin by insertion molding.