LED Illumination Lens Housing Structure for Alignment Accuracy
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Solution Overview
Problem
Existing LED illumination apparatuses face issues with lens positioning and mounting, leading to center alignment errors and defects like sink marks and air bubbles, which affect optical characteristics and require multiple positioning holes, complicating wiring pattern routing.
Innovation Solution
A lens mounting structure for LED illumination apparatuses that reduces the number of positioning holes by using housings with projections and connection parts, allowing lenses to be fixed without additional structures, and a cover to hold the housings in place, facilitating easier wiring design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional structures such as mounting boss parts and mounting holes are provided for positioning and fixing the lens, then the lens can be securely mounted on the LED substrate, but sink marks, air bubbles, and other defects may occur in the molded article, and optical characteristics of the lens body may be affected
Solution Approach 1:
The invention extracts the mounting function from the lens body by providing a separate housing structure with mounting holes. The lens is mounted inside the housing rather than directly on the substrate, which removes the conflicting requirements of mounting reliability and lens molding quality. The housing bears the mounting stress while the lens remains defect-free.
Solution Approach 2:
The invention segments the mounting function from the lens structure by introducing a separate housing component. The housing contains the mounting holes and positioning features, while the lens is merely inserted into the housing cavity. This segmentation allows each component to optimize its own function without compromising the other.
2Measurement precision
If two or more positioning holes are provided in the LED substrate for one lens, then the lens can be accurately positioned, but routing of wiring pattern in the LED substrate needs much elaboration and trial-and-error
Solution Approach 1:
The invention segments the positioning function from the LED substrate by providing positioning holes in the housing rather than in the substrate. The housing acts as an intermediate structure that carries the positioning features, allowing the substrate to maintain simple wiring patterns without multiple positioning holes interfering with the electrical routing.
Solution Approach 2:
The housing serves as an intermediary structure between the LED substrate and the lens. It provides the positioning holes and mounting features needed for accurate lens positioning, while allowing the substrate to maintain its simple wiring pattern design. The housing mediates between the mechanical positioning requirements and the electrical routing requirements.
Data Source
AI summary
An LED illumination apparatus includes a plurality of the LEDs mounted on an LED substrate, a plurality of housings disposed on the LED substrate and each having a projection to be fitted with a corresponding one of a plurality of positioning holes formed in the substrate, a plurality of lenses fixed to the housings, and a cover disposed over the lenses and the housings. Each one of the housings includes connection parts configured to be positioned through fitting between the positioning holes and the projections of an adjacent housing to connect them between the positioning holes and the projections of an adjacent housing connect them together; interconnected housings held in position by the cover.