LED Light Indicator Lens Coupling Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light indicators with LED sources face issues due to adhesive materials damaging the phosphor layer and deteriorating from heat, leading to reduced luminous efficiency and lens separation from the tubular body.
Innovation Solution
A light indicator design featuring a support body with integrated coupling bodies and lenses, where the lenses are securely fixed using elastic coupling bodies that engage with the support body and support plates, eliminating the need for adhesive materials and enhancing heat dissipation through convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive material is used to fix the lens to the tubular body, then the lens can be securely attached, but the adhesive material damages the phosphor layer on the LED and deteriorates from heat causing lens separation
Solution Approach 1:
The patent extracts and eliminates the adhesive material from the lens fixation system. Instead of using adhesive, the invention employs a mechanical retention groove structure integrated into the lens body that engages with the LED module housing, completely removing the harmful adhesive component while maintaining secure attachment.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical retention system. The lens incorporates a retention groove that mechanically engages with corresponding protrusions on the LED module housing, substituting chemical attachment with mechanical interlocking to avoid adhesive-related problems.
2Ease of manufacture
If adhesive material is used to attach the lens, then initial attachment is achieved, but the adhesive deteriorates due to LED heat generation leading to lens separation
Solution Approach 1:
The patent replaces the heat-sensitive adhesive bonding system with a thermally stable mechanical retention system. The retention groove and engaging protrusion create a heat-resistant mechanical connection that maintains lens attachment durability under LED operating temperatures without degradation.
Solution Approach 2:
The patent changes the attachment mechanism from chemical bonding to mechanical interlocking, fundamentally altering the parameter of attachment method. This parameter change enables the system to withstand high temperatures without the deterioration issues inherent in adhesive materials.
3Ease of manufacture
If adhesive material is employed for lens fixation, then lens positioning is achieved, but the adhesive contacts the LED and damages the phosphor layer reducing luminous efficiency
Solution Approach 1:
The patent extracts the adhesive material from the assembly process, eliminating the source of phosphor layer damage. The mechanical retention groove system provides lens positioning and fixation without requiring any adhesive material that could contact and damage the LED phosphor coating.
Solution Approach 2:
The retention groove structure serves as an intermediary mechanism between the lens and LED module housing. It provides the necessary positioning and attachment function without introducing adhesive material that could harm the phosphor layer, thus protecting luminous efficiency.
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 provides a structurally simple, efficient, and long-lasting light indicator with improved heat management, preventing adhesive-related damage and ensuring stable operation by using elastic coupling to secure lenses without adhesives and facilitating effective heat removal.
Implementation Method 1
each lens is fixed on the external surface of the tubular body in front of the LED, intercepting the light emission axis of the latter, and adapted to concentrate the light emitted by such LED into light beams mainly oriented along a horizontal optical axis
Implementation Method 2
the light indicator comprises at least one coupling body extended between two ends thereof, of which a rear end is engaged with the support body, and a front end provided with at least one first bent portion engaged in abutment against a front face of the corresponding lens in order to retain it integral with the support body
Implementation Method 3
enhancing heat dissipation through convection
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Light indicator which comprises a support body (2) to which multiple rows of LEDs (3) and multiple lenses (4) are fixed, each of which positioned in front of the corresponding row of LEDs (3), and provided with a rear surface (13) directed towards the LEDs (3), and with a front surface (14) directed in the sense opposite the aforesaid rear surface (13). In addition, the light indicator comprises multiple coupling bodies (15), each of which extended between two ends (16, 17) thereof, of which a rear end (16) is engaged with the support body (2), and a front end (17) is provided with a first bent portion (18) engaged in abutment against the front surface (14) of the corresponding lens (4) in order to retain the latter integral with the support body (2) itself.