Integrated Lens Holder for Stage Light Fixture
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Solution Overview
Problem
Existing stage light fixtures with lens holders formed by splicing metal plates suffer from poor integral strength, high complexity in assembly, and significant geometric tolerance issues, leading to potential damage and accuracy problems.
Innovation Solution
An integrated lens holder design featuring a lens mounting ring, support plate, and support pillars that are molded together, reducing parts and geometric tolerance, while incorporating lightening holes and positioning pins for enhanced strength and assembly precision, and allowing for interchangeable side plates to accommodate different specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lens holder is formed by splicing metal plates, then the manufacturing process is simple, but the integral strength is poor and the connection portion is prone to damage
Solution Approach 1:
The patent integrates multiple components (lens holder body, support arms, mounting structures) into a single molded plastic part, eliminating the need for splicing metal plates together. This merging of components resolves the contradiction by providing both high integral strength through monolithic construction and ease of manufacture through injection molding processes.
2Ease of manufacture
If the lens holder is formed by splicing metal plates, then the manufacturing process is simple, but the assembly complexity increases with large number of parts
Solution Approach 1:
The patent combines multiple functional components into a single integrated lens holder assembly that can be manufactured as one piece through injection molding. This eliminates the need for assembling multiple spliced metal plate components, thereby reducing assembly complexity while maintaining manufacturing simplicity through the molding process.
3Ease of manufacture
If the lens holder is formed by splicing metal plates, then the manufacturing process is simple, but the geometric tolerance is poor causing high size errors
Solution Approach 1:
The patent utilizes injection molding to create an integrated lens holder where all geometric features are formed in a single manufacturing process. This eliminates the cumulative tolerance errors that occur when splicing multiple metal plates, achieving high geometric precision while keeping the manufacturing process simple through conventional molding techniques.
4Strength
If the support pillar uses sufficient material for strength, then the strength is adequate, but the weight increases
Solution Approach 1:
The patent employs varying wall thicknesses in the support pillars, with thicker sections at critical load-bearing locations and thinner sections where less strength is required. This local quality variation maintains adequate strength while minimizing overall weight, resolving the contradiction between strength and weight in the lens holder design.
Data Source
AI summary
A stage light fixture with an integrated lens holder includes a light head having a light source and a light-outgoing lens assembly, light emitted from the light source being projected through the light-outgoing lens assembly; and a support arm for supporting the light head to rotate. The light head is provided with a lens mounting ring for fastening the light-outgoing lens assembly, a support plate having a light-passing hole, and a plurality of support pillars for connecting the lens mounting ring to the support plate, which are integrally form the lens holder in an integrated form to accommodate a focusing assembly and/or an amplifying assembly. Compared to the lens holder formed by splicing metal plates, such integrated structure can reduce parts for assembly and reduce geometric tolerance due to multiple process flow, thereby achieving improved assembly accuracy. Meanwhile, the integrated lens holder can strengthen the whole strength thereof.