LED Illuminating Device Lens Snap-Fit Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED retrofit lamps have complex and costly assembly processes due to the need for bolts and additional mechanical structures to fix the circuit board and lens to the heat sink, with low connection reliability and potential damage to ceramic circuit boards.
Innovation Solution
An illuminating device with a heat sink, lens, and circuit board where the lens features snap-fit structures and pressing portions to securely attach to the heat sink without additional mechanical structures, using a biasing device with springs and insulation washers to maintain connection reliability over time, and optionally micro-lens or positioning columns for precise alignment and light adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolts and additional mechanical structures are used to fix the lens and circuit board to the heat sink, then connection reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates multiple functions into the lens: it serves as both the optical element and the fastening component. The snap-fit structures on the lens directly engage with the heat sink to secure both the lens and circuit board, eliminating the need for separate bolts and mechanical fasteners. This merging of functions reduces device complexity while maintaining connection reliability.
Solution Approach 2:
The lens performs self-fastening through its integrated snap-fit structures that automatically engage with corresponding features on the heat sink during assembly. The elastic deformation of the lens material enables automatic locking without requiring additional fastening operations, making the assembly process simpler and more reliable.
2Strength
If bolts are used to fix the circuit board on the heat sink, then connection strength is improved, but ceramic circuit boards may be damaged
Solution Approach 1:
The lens itself serves as the fastening element, using its elastic properties to create a secure connection without applying concentrated mechanical forces that could damage the ceramic circuit board. The distributed pressure from the lens's pressing portion provides adequate fixation strength while avoiding the localized stress concentrations caused by bolts.
Solution Approach 2:
The patent changes the fastening mechanism from rigid mechanical connection (bolts) to elastic deformation-based connection (snap-fit structures). This parameter change allows the lens to exert sufficient holding force while avoiding the damaging concentrated loads that rigid fasteners impose on fragile ceramic substrates.
3Device complexity
If UV glue or double sided adhesive is used to fix the lens, then assembly complexity is reduced, but connection reliability decreases
Solution Approach 1:
The patent replaces chemical bonding methods (UV glue, adhesive) with a mechanical snap-fit system. The mechanical engagement provides immediate, reliable, and reversible connection that is superior to chemical bonding in terms of strength and reliability, while maintaining simple assembly through the elastic nature of the snap-fit structures.
4Reliability
If additional mechanical structures are added to secure components, then connection reliability is improved, but production cost increases
Solution Approach 1:
The lens is designed with integrated snap-fit structures that combine the optical element and fastening function into a single component. This eliminates the need for separate fasteners, reducing the total component count and assembly steps, thereby lowering production costs while maintaining or improving connection reliability.
Solution Approach 2:
The lens serves multiple functions simultaneously: optical focusing, mechanical fastening of the lens itself, and securing of the circuit board. This multi-functionality reduces the overall component count and assembly complexity, leading to lower manufacturing costs without compromising connection reliability.
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
Simplifies assembly, reduces component count and production costs, enhances connection reliability, and prevents damage to ceramic circuit boards, ensuring secure attachment even with component deformation over time.
Implementation Method 1
the lens includes at least one snap-fit structure and at least one pressing portion, and the snap-fit structure snaps into the circumferential wall to fix the lens to the heat sink
Implementation Method 2
a biasing device arranged between the lens and the circuit board, which is used to provide a bias force between the lens and the circuit board. After mounting the lens on the heat sink, the spring is extruded and is in a forced state
Implementation Method 3
LED light sources are more and more welcomed by the people. There are a large number of LED retrofit lamps in the current market. A LED retrofit lamp generally has a heat sink
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Illuminating Device The present invention relates to an illuminating device (100) comprising: a heat sink (1) having a bottom wall (111) and a circumferential wall (112) extending from the bottom wall (111), defining an accommodating cavity (11); a lens (2) arranged at an opening of the accommodating cavity (11); and a circuit board (3) having a light source and being arranged on the bottom wall (111), wherein the lens (2) includes at least one snap-fit structure and at least one pressing portion, and the lens (2) snaps into the circumferential wall (112) to fix the lens (2) to the heat sink (1) and the lens (2) presses the circuit board (3) against the bottom wall (111) through the pressing portion.