Interconnected Lens Housings for Accurate LED Lens Positioning
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Solution Overview
Problem
Existing LED illumination apparatuses face issues with lens positioning and mounting, leading to center alignment errors and defects like sink marks and air bubbles, which affect optical characteristics and require multiple positioning holes, complicating wiring pattern routing.
Innovation Solution
A lens mounting structure for LED illumination apparatuses that reduces the number of positioning holes by using housings with projections and connection parts, allowing lenses to be fixed without additional structures, and a cover to hold the housings in place, facilitating easier wiring design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional structures such as mounting boss parts and mounting holes are provided for positioning and fixing the lens, then the lens can be securely mounted on the LED substrate, but sink marks, air bubbles, and other defects may occur in the molded article, and optical characteristics of the lens body may be affected
Solution Approach 1:
The patent combines the lens housing with the LED substrate by integrating the positioning holes directly into the substrate structure. The housing is formed as a single piece that mounts directly to the substrate without requiring separate boss parts or additional mounting structures, thereby eliminating the defects associated with additional molded structures while maintaining secure mounting.
Solution Approach 2:
The LED substrate serves multiple functions: it provides electrical connections for the LEDs and simultaneously provides positioning holes for mounting the lens housings. This multi-functionality eliminates the need for separate positioning structures and reduces the total number of components, thereby improving manufacturing quality while maintaining mounting reliability.
2Measurement precision
If two or more positioning holes are provided in the LED substrate for one lens, then the lens can be positioned and mounted, but routing of wiring pattern in the LED substrate needs much elaboration and trial-and-error
Solution Approach 1:
The patent divides the positioning function across multiple housings rather than requiring multiple positioning holes per housing. Each housing has its own positioning hole, allowing independent positioning and reducing the need for complex wiring routing around multiple holes in the substrate. The segmentation of positioning responsibilities simplifies the wiring design process.
Solution Approach 2:
The housing acts as an intermediary between the LED substrate and the lens. The positioning hole in the housing provides the necessary positioning function, eliminating the need for multiple positioning holes in the substrate itself. This intermediary structure simplifies the substrate wiring pattern routing while maintaining positioning accuracy.
Data Source
AI summary
An LED illumination apparatus includes a plurality of the LEDs mounted on an LED substrate, a plurality of housings disposed on the LED substrate and each having a projection to be fitted with a corresponding one of a plurality of positioning holes formed in the substrate, a plurality of lenses fixed to the housings, and a cover disposed over the lenses and the housings. Each one of the housings includes connection parts configured to be positioned through fitting between the positioning holes and the projections of an adjacent housing to connect them between the positioning holes and the projections of an adjacent housing connect them together; interconnected housings held in position by the cover.