LED Lens Positioning Structure for Precise Optical Axis Alignment
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Solution Overview
Problem
Existing LED light sources face challenges in accurately positioning light-transmissive parts, such as optical lenses, relative to LEDs on printed boards, which affects the desired light distribution pattern and evenness.
Innovation Solution
The proposed solution involves an LED light source design that includes holders with protrusions on a printed board to guide and position a light-transmissive part, using an adhesive to secure the supporter and board together, allowing for precise alignment and positioning of the light-transmissive part relative to the LED, facilitated by self-alignment during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mounting methods are used to attach light-transmissive parts to printed boards, then the manufacturing process is simple, but the positioning accuracy of the light-transmissive part relative to the LED is poor
Solution Approach 1:
The mounting structure is segmented into distinct functional elements: protrusions on the printed board serve as positioning references, while recesses on the light-transmissive part serve as engagement features. This segmentation allows independent optimization of positioning accuracy without complicating the overall assembly process
Solution Approach 2:
The protrusions on the printed board act as intermediary positioning elements that mediate between the board surface and the light-transmissive part. These protrusions engage with corresponding recesses to establish precise relative positioning without requiring complex alignment mechanisms
2Manufacturing precision
If the light-transmissive part is positioned without precise alignment features, then the manufacturing process is faster, but the optical axis alignment between LED and light-transmissive part is inaccurate
Solution Approach 1:
The protrusions are pre-formed on the printed board at precise locations corresponding to LED mounting positions. This preliminary positioning structure enables the light-transmissive part to be automatically aligned during attachment, eliminating time-consuming alignment operations while ensuring accurate optical axis alignment
Solution Approach 2:
The recesses on the light-transmissive part and protrusions on the board create a self-aligning mechanism. When the light-transmissive part is attached, the recesses automatically engage with the protrusions, causing the part to self-position relative to the LED without requiring external alignment tools 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 approach enhances the accuracy of positioning both the LED and light-transmissive part, reducing displacement and ensuring a consistent light distribution pattern, thereby improving the light evenness and optical axis alignment.
Implementation Method 1
The adhesive bonds the supporter and the board together
Implementation Method 2
The light-transmissive part refracts light emitted by the LED so as to direct the light outward
Data Source
AI summary
An LED light source includes a board, a holder, an LED, a fastener, a lens, a supporter, and an adhesive. The board has a first surface. The holder is arranged on or above the first surface. The LED is arranged on or above the first surface. The fastener fastens the LED to the first surface. The lens has an exterior shape larger than the LED as viewed in a plan view, and is arranged on or above an LED upper surface to refract LED light so as to direct the light outward. The supporter is arranged on an exterior with respect to the LED as viewed in a plan view on a lens surface facing the first surface. The supporter is held by the holder for positioning of the lens at a predetermined position on the first surface. The adhesive bonds the supporter and the board together.