Integrated Lens Assembly for LED Modules
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Solution Overview
Problem
Current LED lamp manufacturing processes are complex and inefficient due to separate lens units and inconvenient assembly methods, which affect quality and cost, and there is a need for a safer and more reliable LED light source module.
Innovation Solution
An integrated LED light source module with a light source plate, an integrated lens assembly, and magnetic or mechanical connecting elements that allow for easy assembly and secure attachment to a base, ensuring safety and reliability while maximizing thermal radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate lens units are used for each LED unit, then each LED can be individually covered, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple separate lens units into a single integrated lens assembly that covers multiple LED units simultaneously. This integration eliminates the need for separate lens units while maintaining individual LED coverage, thereby simplifying the manufacturing process and reducing complexity without compromising quality.
Solution Approach 2:
The integrated lens assembly serves multiple functions: it covers and protects multiple LED units, provides structural support, and enables secondary optical distribution for all LEDs through a unified design. This multi-functional approach replaces what would otherwise require multiple separate components.
2Reliability
If separate lens units are arranged on the light source plate, then each LED is covered, but additional protecting covers are needed for uncovered circuit areas
Solution Approach 1:
The integrated lens assembly merges the functions of multiple lens units and the additional protecting cover into a single unified structure. This assembly not only covers the LED units but also provides protection for the underlying circuit board areas, eliminating the need for separate protecting covers.
Solution Approach 2:
The integrated lens assembly performs multiple protective functions simultaneously: it protects the LED units from above and provides structural coverage for the circuit board areas beneath it, serving as both an optical element and a protective enclosure.
3Reliability
If screws are used to fix the light source module on the base, then the connection is secure, but the assembly and disassembly process is inconvenient
Solution Approach 1:
The patent replaces the traditional mechanical screw-based fixing system with a magnetic connection system. The magnetic elements provide secure attachment through magnetic attraction while allowing for easy assembly and disassembly by simply bringing components together or pulling them apart, eliminating the need for tools and complex manipulation.
4Ease of operation
If magnetic elements are used to adsorb the lamp onto the fixing mechanism, then assembly convenience is improved, but the risk of disengagement increases
Solution Approach 1:
The patent combines magnetic elements with mechanical connecting elements in a hybrid fixing system. The magnetic elements provide initial attraction and alignment for easy assembly, while the mechanical elements (such as clips or latches) engage to provide secure mechanical interlocking that prevents accidental disengagement, thus combining the advantages of both systems.
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 simplifies the assembly process, enhances safety and reliability, and maintains effective light distribution and thermal management, making the LED lamp more efficient and cost-effective.
Implementation Method 1
A plurality of magnetic elements, or magnetic elements and mechanical connecting elements, run through the integrated lens assembly and the light source plate and are adsorbed and/or assembled on the base
Data Source
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AI summary
An LED light source module comprises a light source plate (10) that has a first surface and a second surface opposite to each other, wherein several LED light sources (11) are attached on the first surface, and the second surface faces and is assembled on a base plate used as the installation foundation; a power driving module (40), configured to be electrically connected to the light source plate (10); and an integrated lens assembly (20), fixed on the light source plate (10), covered outside the first surface of the light source plate (10) and having several lens units (24) respectively capped outside the corresponding LED light sources (11), wherein the integrated lens assembly (20) is configured to have an accommodating space (25) and the power driving module (40) is accommodated in the accommodating space (25). An LED lamp comprises a base plate used as the installation foundation and the LED light source module. The LED lamp and the LED light source module thereof have simple structures, are easy to assemble and are safe and reliable, have a simple and convenient production process, and have high production efficiency.