LED Light Fixture Lens Alignment via Mating Features
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Solution Overview
Problem
Existing LED light fixtures for high-luminance applications like roadway lighting face challenges in achieving high-precision lens alignment while maintaining efficient and cost-effective manufacturing processes, as they often require complex reflectors and varying orientations of light sources to achieve desired illumination patterns.
Innovation Solution
A method for assembling LED light fixtures with high-precision lens alignment using a one-piece lensing member and a circuit board, where alignment is facilitated by mating features such as protrusions and holes, and fasteners, allowing for accurate alignment of secondary lenses over primary lenses without the need for complex reflectors or multiple light source orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If complex reflectors and varying orientations of multiple light sources are used to achieve desired illumination patterns, then light distribution performance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the light distribution function from complex reflectors and multi-orientation light source configurations, consolidating it into a single integrated lens system that performs the same illumination function with simpler structure
Solution Approach 2:
The patent merges multiple light sources into a single LED array and combines the light distribution function into an integrated lens system, reducing the number of components while maintaining illumination performance
2Manufacturing precision
If high-precision lens alignment is achieved through traditional manufacturing methods, then lens alignment precision is improved, but manufacturing efficiency decreases and cost increases
Solution Approach 1:
The patent incorporates alignment features directly into the mold during lens manufacturing, so that alignment precision is built into the component itself before assembly, eliminating the need for post-manufacturing alignment adjustments
Solution Approach 2:
The alignment features on the lens automatically guide and establish precise alignment with the LED array during assembly, allowing the component to self-align without requiring complex external alignment equipment or procedures
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
This method enables precise light distribution while ensuring efficient assembly and cost-effective manufacturing, providing a high-precision lens alignment that maximizes performance in high-luminance LED light fixtures for applications like roadway lighting.
Implementation Method 1
a heat-conductive structure having a mounting surface
Data Source
AI summary
LED lighting apparatus including (1) a plurality of primary lenses each over a corresponding one of LED arrays spaced on a circuit board, and (2) a one-piece lensing member over the circuit board and having a plurality of secondary lenses each spaced over one of the primary lenses on the circuit board, the circuit board and lensing member having first and second mating features positioned and configured for inter-engagement for high-precision lens alignment. The circuit board and one-piece lensing member are each joined to a mounting surface of a heat-conductive member, and such assembly, while facilitating high-efficiency assembly, does not interfere with high-precision lens alignment.