LED Lamp Lens Snap-Fit Assembly for Rapid Production
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Solution Overview
Problem
The existing assembly process for LED reflector lamps is laborious and time-consuming, requiring multiple steps and components to be individually fastened within the housing, often involving adhesive curing times that reduce production line throughput.
Innovation Solution
A lighting device design where the light module is connected to the lens via snap-on or thermal forming processes, allowing the module-lens unit to be easily inserted into the housing, eliminating the need for individual component installation and adhesive curing times, with snap-fit elements or formed lens sections providing secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to fasten components, then reliable connection is achieved, but production time increases due to adhesive curing time
Solution Approach 1:
The patent replaces adhesive bonding (chemical connection) with mechanical snap-fit connections. The lens holder features snap-fit elements that mechanically engage with the housing, eliminating the need for adhesive curing time while maintaining reliable connection. This mechanical substitution directly resolves the contradiction between connection reliability and production throughput.
2Reliability
If multiple individual components are fastened separately in the housing, then secure assembly is achieved, but assembly complexity and time increase
Solution Approach 1:
The patent merges the lens and lens holder into a pre-assembled unit where the lens is already secured to the lens holder via snap-fit connections. This merged unit is then installed as a single component into the housing, reducing assembly complexity while maintaining secure assembly. The merging principle eliminates multiple separate fastening operations.
Solution Approach 2:
The lens and lens holder are pre-assembled and pre-secured using snap-fit connections before installation into the housing. This preliminary action ensures the lens is securely positioned and reduces the complexity of the final assembly step, as the lens unit is already prepared and secured.
3Manufacturing precision
If precise tolerances and undercuts are provided in the housing for fastening components, then accurate positioning is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the fastening mechanism from requiring precise tolerances and undercuts in the housing to using snap-fit elements on the lens holder that engage with corresponding features on the housing. This parameter change in the connection method reduces manufacturing precision requirements for the housing while maintaining accurate positioning of the lens assembly.
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 approach simplifies assembly, reduces production time, and eliminates the need for precise tolerances and undercuts, enhancing manufacturing efficiency and reducing assembly effort.
Implementation Method 1
the lens section is heated to a temperature at which the material of the lens section becomes plastically deformable
Implementation Method 2
the lens section is formed in such a way that it engages with corresponding sections of the housing and the lens and thereby connects said lens to said housing
Data Source
AI summary
A lighting device (in particular an MR-16 or a PAR-16 lamp) comprises a housing and a lens. A light module having a light source and a driver is attached to the lens. The lens is connected to the housing by means of a snap-on connection or by means of a formed (thermally, for example) edge section.