LED Lens Fixing Element for Sealed Optical Assembly
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Solution Overview
Problem
LED lighting devices face challenges in maintaining water resistance, heat dispersion, and mechanical vibration resistance, which affect their performance and longevity due to sensitivity to humidity, temperature, and mechanical vibrations.
Innovation Solution
The design incorporates a separate fixing element with a first part that applies pressure to the lens component, forming a closed accommodating space with a gasket, ensuring the LED element is sealed and protected, and allowing for the use of materials with varying elasticity and strength for the lens and fixing components, reducing mold costs and increasing material options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lens component and fixing component are integrated into a single structure, then the device complexity is reduced, but the material selection is limited and mold costs increase
Solution Approach 1:
The patent divides the lens component and fixing component into separate parts. The lens component (130) is separated from the fixing element (250), allowing each to be manufactured independently with optimized materials and molds. This segmentation reduces the complexity of individual molds while maintaining overall structural simplicity through the assembly of these separate components.
2Ease of manufacture
If the lens component is made from a single material type, then the manufacturing process is simplified, but the ability to optimize for both elasticity and strength is reduced
Solution Approach 1:
The patent employs different materials for the lens component and fixing element based on their specific functional requirements. The lens component can be made from materials optimized for optical properties and elasticity, while the fixing element uses materials optimized for mechanical strength and rigidity. This composite material approach allows each component to be manufactured with its optimal material properties.
3Device complexity
If the lens component is directly fixed to the base without a separate fixing element, then the device complexity is reduced, but the lens component may protrude and affect light distribution
Solution Approach 1:
The patent introduces a separate fixing element (250) as an intermediary component between the lens component (130) and the base (110). This fixing element serves as a mediator that provides precise positioning and stable fixation, preventing lens protrusion while maintaining consistent light distribution. The intermediary fixing element ensures reliable optical performance without requiring direct integration of the lens with the base.
4Strength
If the lens component is made from rigid material, then the structural strength is improved, but the ability to form effective seals with elastic materials is reduced
Solution Approach 1:
The patent applies different material properties to different parts of the lens assembly based on local functional requirements. The main body of the lens component uses rigid material for structural strength, while specific sealing surfaces or adjacent components use elastic materials to ensure effective sealing. This local differentiation of material quality allows both structural integrity and sealing effectiveness to be achieved simultaneously.
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 solution enhances the durability and reliability of LED lighting devices by preventing lens component protrusion, ensuring consistent light distribution, and simplifying mold manufacturing while maintaining effective sealing and mechanical performance.
Implementation Method 1
The gasket 240 is pressed between the lens component 230 and the base 210, subjected to elastic deformation, and tightly attached to surfaces of the lens component 230 and the base 210.
Implementation Method 2
a fixing element, including a first part which is disposed on a side of the lens component opposite to the base and faces a part of the lens component, and a second part extended from the first part and connected with the base, and the first part of the fixing element being configured to apply a pressure towards the base to the lens component.
Data Source
Figure 1~2a
Figure 2b~3
Figure 4~5
AI summary
A light emitting diode (LED) lighting device and assembly method thereof. The LED lighting device comprises: a base (210) having a mounting surface (211); an LED element (220) disposed on the mounting surface (211) of the base (210); a lens component (230) disposed at a side of the mounting surface (211) of the base (210); a gasket (240) disposed between the base (210) and the lens component (230), such that the LED element (220) is located within an area surrounded by the gasket (240); a fastener (250) comprising a first portion (251) and a second portion (252), wherein the first component is disposed at the side of the lens component (230) opposite to the base (210) and facing a portion of the lens component (230), the second portion extends from the first potion (251) and is connected to the base (210), and the first portion (251) of the fastener (250) applies a pressure on the lens component (230) towards the base (210).