Light Emitting Module Concave Lens Housing Drainage
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Solution Overview
Problem
Existing light emitting modules with small LED lenses face issues of light blocking and water accumulation due to packaging materials, leading to reduced waterproof performance and dust accumulation, which increases production costs and reduces industrial applicability.
Innovation Solution
A light emitting module design featuring a concave arc-shaped first region around the lens exit surface and orthogonal second concave regions within the encapsulating housing, allowing for effective drainage of water and minimizing light obstruction, while using a low pressure molding process for encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the LED lens size is increased to prevent light blocking by packaging material, then light transmission is improved, but the overall module volume increases and production cost rises
Solution Approach 1:
The patent applies local quality by creating a specific regional structure (convex region) at the light emission area of the encapsulating housing. This localized structural modification allows the housing to be transparent to light in the critical emission zone while maintaining normal encapsulation function elsewhere, thus preventing light blocking without requiring an overall increase in lens size or module volume.
2Illumination intensity
If grooves are provided around the LED lens to prevent light blocking, then light transmission is improved, but water accumulation and dust gathering occur reducing waterproof performance
Solution Approach 1:
The patent employs curvature by designing the light-transmissive region as a convex structure that curves outward. This curved surface prevents water and dust from accumulating, as there are no horizontal surfaces or grooves where contaminants can collect. The convex shape allows water to naturally drain off and prevents the formation of water pockets, thereby maintaining waterproof performance while still allowing light transmission.
3Reliability
If packaging material is used to encapsulate the LED module, then waterproof performance is improved, but light emission is blocked
Solution Approach 1:
The patent applies segmentation by dividing the encapsulating housing into distinct functional regions: a light-transmissive convex region at the light emission area and a normal encapsulation region elsewhere. This segmented structure allows different parts of the housing to perform different functions - the convex region prioritizes light transmission while the rest of the housing provides waterproof encapsulation, thus resolving the contradiction between these two requirements.
4Volume of moving object
If a small LED lens is used to reduce module volume, then production cost is reduced, but light transmission is blocked by packaging material
Solution Approach 1:
The patent applies local quality by creating a specific regional structure (convex region) at the light emission area of the encapsulating housing. This localized structural modification allows the housing to be transparent to light in the critical emission zone while maintaining normal encapsulation function elsewhere, thus preventing light blocking without requiring an overall increase in lens size or module volume.
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 prevents light blocking, ensures effective waterproofing, and reduces dust accumulation, maintaining a compact module size with improved production efficiency and appearance.
Implementation Method 1
the second concave region is designed in such a way that water in the first concave region is drained via the second concave region
Data Source
AI summary
A light emitting module may include: a PCB board; a light emitting assembly mounted on the PCB board; a lens and an encapsulating housing, the encapsulating housing encapsulating therein the PCB board, the light emitting assembly and part of the lens, and an exit surface of the lens being exposed out of the encapsulating housing, wherein the encapsulating housing is formed therein with a first concave region surrounding the exit surface and reducing light blocking, and at least a second concave region into the first concave region, wherein the second concave region is designed in such a way that water in the first concave region is drained via the second concave region.