LED Lens Structure Inclined Surface Light Leakage Prevention
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Solution Overview
Problem
LED light source packages face issues with light leakage between the lens structure and circuit board, ejector pin marks, and whirling due to the round surface of the lower corner of the lens structure, which affect the uniformity of light emission and the structural integrity of the package.
Innovation Solution
The LED light source package design includes a first inclined surface on the lens structure that projects towards the light source, with a specific gap configuration between the lens legs and the circuit board, and features projecting columns and intaglio grooves to prevent light leakage and ejector pin marks, while a second inclined surface addresses the whirling issue by altering the light path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lens structure is directly mounted on the circuit board, then the structure is simple, but light leakage occurs between the lens legs and the circuit board
Solution Approach 1:
A light blocking member is introduced as an intermediary component between the lens structure and the circuit board. This member fills the gap formed by the lens legs and the circuit board, preventing light from leaking through the space without requiring complex modifications to the lens legs themselves.
Solution Approach 2:
The light blocking member is specifically positioned only where light leakage occurs - in the gap between the lens legs and the circuit board. This localized solution addresses the harmful effect precisely where it manifests, rather than requiring a complete redesign of the entire mounting structure.
2Ease of manufacture
If ejector pins are used to remove the lens structure from the mold, then the manufacturing process is simple, but ejector pin marks are formed on the lens structure
Solution Approach 1:
The ejection function is extracted from direct contact with the optical surface of the lens structure. Ejector pins are positioned to contact only the non-optical portions of the lens structure, separating the ejection mechanism from the sensitive optical surface and preventing mark formation.
Solution Approach 2:
The lens legs serve as an intermediary structure that transfers the ejection force from the ejector pins to the lens structure without directly contacting the optical surface. This intermediary mechanism allows for easy mold removal while protecting the optical quality.
3Ease of manufacture
If the lower corner of the lens structure has a round surface, then the mold design is simple, but whirling occurs in the light emission
Solution Approach 1:
The inclined surface is applied specifically to the lower corner portion of the lens structure where the round surface causes whirling. This localized modification changes the light path only in the problematic area, correcting the whirling effect without requiring a complete change to the overall lens geometry or mold design.
4Object-generated harmful factors
If the gap between lens legs and circuit board is reduced, then light leakage is prevented, but the lens structure cannot be properly mounted
Solution Approach 1:
The light blocking member acts as an intermediary that fills the gap between the lens legs and the circuit board. This allows the lens structure to maintain its mounting geometry with adequate clearance for proper assembly, while the light blocking member prevents light from passing through the gap.
Solution Approach 2:
The mounting structure is segmented into functional components: the lens legs provide mechanical support and positioning, while the separate light blocking member provides optical shielding. This segmentation allows each component to perform its specific function without compromise.
Data Source
AI summary
Provided is a LED light source package comprising a circuit board, a light source seated on an upper portion of the circuit board, and a lens structure arranged on the upper portion of the circuit board via the light source. A surface that faces the light source in the lens structure includes a first inclined surface that projects toward the light source as going to a center portion of the lens structure.