Integrated Lens Structure for Resistor Shielding in LED Lamps
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Solution Overview
Problem
Existing LED lamp beads are prone to overheating and damage due to excessive current, necessitating additional structures for current limiting resistors and shock prevention, which increases lamp size.
Innovation Solution
A lens design with integrated resistor accommodating grooves and reflective surfaces, allowing resistors to be shielded within the lens body, reducing the need for external protective structures and enhancing illumination uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional structures for installing resistors and preventing electric shock are disposed on the lighting lamp, then the safety and current limiting function are improved, but the lamp size is increased
Solution Approach 1:
The patent combines the resistor installation structure and shock prevention structure into a single integrated lens body. The lens body includes a light source accommodating groove for the LED and a resistor accommodating groove for the resistor, with the resistor groove positioned on the outer side of the light source groove. The lens material itself provides electrical insulation for shock prevention, eliminating the need for separate protective housings or additional structural components.
Solution Approach 2:
The lens body serves multiple functions simultaneously: it focuses and transmits light, accommodates both the light source and resistor, provides electrical insulation for shock prevention, and offers mechanical support. This multi-functional design allows the lens to replace what would traditionally require separate components, thereby reducing overall lamp size while maintaining safety and current limiting functions.
2Reliability
If resistors are installed in separate protective structures, then the current limiting function is improved, but the device complexity is increased
Solution Approach 1:
The resistor accommodating groove is integrated directly into the lens body structure, eliminating the need for separate resistor housings or mounting brackets. The lens body itself becomes the protective structure, reducing the number of parts and simplifying the overall device architecture while maintaining current limiting functionality.
Solution Approach 2:
The lens body is designed to perform multiple functions including light focusing, resistor mounting, and electrical insulation. This multi-functionality reduces device complexity by eliminating the need for separate components dedicated to each function, as the lens structure itself fulfills multiple roles simultaneously.
3Volume of moving object
If the lens body integrates both light source and resistor accommodating grooves, then the lamp size is reduced, but the manufacturing precision requirement is increased
Solution Approach 1:
The lens body is segmented into distinct functional zones: a light source accommodating groove on the inner side and a resistor accommodating groove on the outer side. This segmentation allows for optimized positioning of each component within its designated zone, reducing interference between components and simplifying the precision requirements compared to a fully integrated single-zone design.
Solution Approach 2:
The patent positions the light source groove and resistor groove in different radial dimensions of the lens body, with the light source groove on the inner side and the resistor groove on the outer side. This spatial arrangement in different dimensions allows both components to coexist without excessive precision requirements, as they occupy different zones along the radial direction rather than requiring precise lateral alignment.
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 effectively protects resistors, prevents electric shock, and reduces lamp size while improving illumination uniformity and efficiency.
Implementation Method 1
at least one side of each of the resistor accommodating grooves is configured with a reflective surface disposed opposite to the light exiting surface
Implementation Method 2
the illumination range of the light source is expanded through the refraction of the lens body
Data Source
Figure 1~2
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Figure 4
AI summary
The present application relates to the technical field of illumination, and provides a lens and a lighting lamp. The lens of the present application comprises: a lens body, a light source accommodating recess formed on one side of the lens body and used for accommodating a light source, and a resistor accommodating recess located outside the light source accommodating recess and used for accommodating a resistor. A light incident surface is formed on the inner surface of the light source accommodating recess, and a light emitting surface is formed on the other side of the lens body opposite to the light source accommodating recess. According to the lens of the present application, by providing the resistor accommodating recess used for accommodating a resistor, the resistor is accommodated in the lens body, there is no need to mount an additional protection structure, the size of the whole lamp is reduced, and the problem in the prior art that the size of the lamp is increased due to the fact that a structure for mounting a resistor and preventing an electric shock is additionally arranged on the lamp is effectively solved.