LED Module Lens Ring Support Asymmetry Alignment
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Solution Overview
Problem
Existing light emitting diode (LED) modules face challenges in precision attachment and productivity due to complex fastening structures between optical lenses and bulk feeders, leading to alignment issues and reduced efficiency.
Innovation Solution
A light emitting diode (LED) module design featuring an optical lens with a dome-shaped body and a ring-shaped supporting portion protruding from its lower surface, which includes arcs arranged in an imaginary circle, allowing for precise alignment and simplified mounting without directional requirements, thereby improving attachment precision and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a complex fastening structure is used between optical lens and bulk feeder, then the lens can be securely fastened, but the alignment precision and productivity are reduced due to directionality requirements and additional alignment steps
Solution Approach 1:
The patent applies asymmetry by designing the supporting portion with a specific geometric configuration (arc-shaped structure with defined radius and thickness) that provides secure fastening while eliminating directional constraints. The asymmetric design of the supporting portion allows it to engage with the bulk feeder in a single orientation, thereby removing the need for additional alignment steps while maintaining strong attachment.
Solution Approach 2:
The patent segments the fastening function from the alignment function. The supporting portion is designed as a separate structural element that provides both mechanical support and attachment functionality. By segmenting the lens body from the supporting portion, the design allows the supporting portion to handle fastening requirements independently, simplifying the overall attachment process and improving alignment precision.
2Strength
If a complex fastening structure with directionality is used, then the lens can be securely attached, but the productivity is reduced due to additional alignment steps
Solution Approach 1:
The asymmetric design of the supporting portion with its specific arc geometry provides inherent directional guidance that eliminates the need for complex alignment procedures. The unique geometric configuration ensures that the lens can only be attached in the correct orientation, thereby maintaining secure attachment while significantly improving mounting productivity by reducing or eliminating additional alignment steps.
Solution Approach 2:
The supporting portion design enables self-alignment during the attachment process. The geometric features of the supporting portion (arc-shaped configuration with specific dimensions) automatically guide the lens into the correct position as it is being attached to the bulk feeder, eliminating the need for separate alignment operations and thereby improving productivity.
3Manufacturing precision
If arcs are arranged in an imaginary circle at constant distance from groove center, then alignment precision is improved by eliminating directionality, but the structural complexity increases
Solution Approach 1:
The patent uses asymmetry in the supporting portion design where arcs are arranged in an imaginary circle at a constant distance from the groove center. This asymmetric radial arrangement provides alignment precision by eliminating directional constraints while maintaining structural simplicity. The arcs are positioned to provide uniform support without requiring complex additional structures.
Solution Approach 2:
The supporting portion incorporates curved arc elements arranged in a circular pattern around the groove center. This spherical/circular arrangement provides uniform radial support and eliminates directional preferences, improving alignment precision. The curved geometry of the arcs simplifies the overall structure compared to angular or irregular configurations while maintaining the desired alignment properties.
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 design enhances optical efficiency and manufacturing productivity by simplifying the alignment and bonding process, reducing the risk of lens jamming and scratches during transport, and ensuring stable bonding between the optical lens and substrate.
Implementation Method 1
The supporting portion and the substrate may be secured to each other via an adhesive, and the adhesive may be formed in a portion of a region in which the substrate and the supporting portion adjoin each other.
Data Source
AI summary
Provided is a light emitting diode (LED) module. The LED module includes: a light emitting chip on a substrate; and an optical lens on the substrate configured to envelop the light emitting chip, wherein the optical lens includes a body comprising a groove receiving the light emitting chip therein and having a dome-shaped upper surface and a ring-shaped supporting portion protruding from a lower surface of the body.