Integrated LED Lens Assembly with Magnetic Mounting

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Solution Overview

Problem

The existing LED lamp manufacturing process is complex due to separate lens units and assembly inefficiencies, including the use of screws and magnetic elements which can lead to disengagement issues.

Innovation Solution

An integrated LED light source module with a light source plate, power driving module, and integrated lens assembly that includes magnetic elements and accommodating spaces for easy assembly and protection, using a detachable connection mechanism such as elastic fasteners or jaws for secure fixation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate lens units are arranged on the light source plate, then each LED unit can be covered individually, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improvecoverage of each LED unitVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple separate lens units are merged into a single integrated lens assembly that covers the entire light source plate. This integration reduces the number of separate components from multiple individual lens units to one unified assembly, simplifying the manufacturing process while maintaining coverage over all LED units.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated lens assembly serves multiple functions simultaneously: it acts as a protective cover for the light source plate, provides lens coverage for all LED units, and eliminates the need for separate protecting covers. This multi-functionality reduces overall device complexity while maintaining all necessary protective and optical functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If separate lens units are arranged on the light source plate, then each LED unit can be covered individually, but assembly time and work are wasted

Engineering Contradiction:

Improvecoverage of each LED unitVSAvoidassembly efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated lens assembly is pre-configured with multiple lens units and protective cover features built-in during manufacturing. This preliminary integration means that during final assembly, the entire assembly is installed as one unit rather than requiring sequential installation of multiple separate lens units, significantly reducing assembly time.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If screws are used to fix the light source module on the base, then the connection is secure, but the assembly and disassembly process is inconvenient

Engineering Contradiction:

Improveconnection securityVSAvoidassembly convenience

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The traditional mechanical screw-based fastening system is replaced with a magnetic connection system. Magnetic elements embedded in the integrated lens assembly interact with magnetic elements in the base to provide secure holding force, eliminating the need for tools and manual screw operations while maintaining reliable connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If magnetic connecting elements are used to adsorb the lamp, then assembly convenience is improved, but the risk of disengagement increases

Engineering Contradiction:

Improveassembly convenienceVSAvoidconnection stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Multiple magnetic elements are distributed across the integrated lens assembly and base, creating multiple simultaneous magnetic connection points. This distributed magnetic field provides cumulative holding force that maintains secure connection while allowing easy assembly and disassembly through simple approach and separation movements.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies the manufacturing process, enhances assembly convenience, ensures safety and reliability, and maintains effective thermal conductivity and light diffusion, while reducing the risk of disengagement and improving assembly efficiency.

Implementation Method 1

at least two magnetic elements assembled into the integrated lens assembly... the at least two magnetic elements are at least partially accommodated into the accommodating portions

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentUS10401002B2LED lamp and LED light source module thereof

Publication Date: 2019.09.03 OPPLE LIGHTING CO LTD

AI summary

An LED light source module is provided and includes: a light source plate that has a first surface and a second surface opposite to each other, where several LED light sources are attached on the first surface; a power driving module, configured to be electrically connected to the light source plate; and an integrated lens assembly, fixed on the light source plate and having several lens units respectively capped outside the corresponding LED light sources, where the integrated lens assembly is configured to have an accommodating space and the power driving module is accommodated in the accommodating space, and magnetic elements and/or mechanical connecting elements are assembled into the integrated lens assembly and run through the light source plate and are adsorbed and/or assembled on the base.