LED Lens Module Clip Support for High-Temperature Adhesion
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Solution Overview
Problem
The detachment of optical lenses from light emitting diode (LED) packages due to the flow of glue during curing and reduced adhesive characteristics at high temperatures, leading to potential detachment and compromised waterproof performance.
Innovation Solution
Incorporation of a support member, such as a metal sheet, with humps and clips, to increase the contact area and adhesion between the glue and the substrate, and provide elasticity for secure fastening of the lens unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glue is used to attach the optical lens to the LED package, then the lens can be secured to the substrate, but the glue may flow during curing causing arrangement location shift and reduced adhesion at high temperatures leading to detachment
Solution Approach 1:
The support member is divided into multiple functional segments: a base portion for mounting on the substrate, a protruding portion extending toward the lens, and a clipping portion for securing the lens. This segmentation allows each part to perform its specific function optimally while working together as a unified support structure.
Solution Approach 2:
The support member is pre-installed on the substrate before the lens is attached. The protruding portion is positioned in advance to guide and support the lens during assembly, ensuring correct arrangement location and preventing glue flow from causing misalignment.
Solution Approach 3:
The support member acts as an intermediary structure between the substrate and the lens. Instead of relying solely on glue to provide both structural support and adhesion, the support member provides mechanical support while the glue provides bonding, separating these functions and improving overall attachment reliability.
2Ease of manufacture
If organic-based glue material is used, then the lens can be attached to the substrate, but the glue characteristics are reduced at high temperatures causing detachment
Solution Approach 1:
The attachment system uses a composite approach combining the support member (made of temperature-resistant material such as metal or ceramic) with organic-based glue material. The support member provides high-temperature structural support while the glue provides bonding, allowing the system to withstand high temperatures without losing attachment capability.
3Strength
If the contact area between the support member and glue is increased, then the adhesion is improved, but the device complexity increases
Solution Approach 1:
The support member extends in the vertical dimension with a protruding portion that reaches toward the lens, increasing the contact area with the glue without expanding the horizontal footprint. This dimensional approach enhances adhesion while maintaining a compact device structure.
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
Prevents detachment of the lens from the substrate, ensuring stable adhesion and maintaining waterproof integrity of the lens module.
Implementation Method 1
The support member may include a hump for increasing a contact area between the support member and the glue
Implementation Method 2
the clip holder may have elasticity such that a shape thereof is deformed when an external force in a Z-axis direction perpendicular to the substrate is applied, the shape of the clip holder may be deformed such that the clip and an end of the lens unit are fastened, and thereafter, when the clip and the lens unit are fastened, the deformed shape of the clip holder may be restored
Implementation Method 3
a glue contacting the substrate and the lens unit to secure the substrate and the lens unit
Data Source
AI summary
A light module including a substrate, a light emitter disposed on the substrate and including a plurality of light emitting devices, a lens disposed on the substrate and the light emitter, and a supporter configured to be connected to a region of the lens, in which the lens includes a curved region and a flat region, and the supporter includes a protruding region extended from the substrate in a direction substantially perpendicular to the substrate and a clip region connected to a region of an end of the lens.