LED Module Threaded Lens Base Connection
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Solution Overview
Problem
Existing LED module connections, such as screw or snap-fitting, result in insecure and poorly sealed connections between the lens assembly and the radiator due to limited force bearing points and uneven force distribution, leading to installation difficulties and poor sealing performance.
Innovation Solution
The LED module employs a threaded connection between the lens assembly and the base, utilizing a sealing ring with matching structures and a stepped design to create a secure, even force distribution and enhanced sealing, along with a sealant for additional sealing efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If screw or snap-fitting connection is used between lens assembly and radiator, then installation is simplified, but connection security and sealing performance deteriorate due to limited force bearing points and uneven force distribution
Solution Approach 1:
The connection interface is segmented into multiple threaded engagement points around the circumference, transforming a single-point connection into a distributed multi-point connection system. The lens assembly features an annular threaded portion that engages with the radiator's threaded structure at multiple locations simultaneously, ensuring even force distribution and secure connection.
Solution Approach 2:
The connection transitions from a planar snap-fitting or single-axis screw connection to a three-dimensional threaded engagement. The threaded structure provides radial and axial force components, creating a more robust connection that resists both lateral and longitudinal stresses while maintaining sealing pressure.
2Device complexity
If screw or snap-fitting connection is used between lens assembly and radiator, then device complexity is reduced, but sealing performance deteriorates due to small and uneven force bearing area
Solution Approach 1:
The sealing interface is segmented into multiple contact zones along the threaded engagement, creating numerous small sealing points that collectively provide comprehensive sealing coverage. The sealing ring or O-ring is compressed at multiple locations by the threaded structure, preventing leakage paths.
Solution Approach 2:
A dedicated sealing ring or O-ring is introduced as an intermediary element between the lens assembly and radiator. This sealing component is compressed by the threaded connection to create a reliable seal, decoupling the mechanical fastening function from the sealing function and optimizing both independently.
3Reliability
If threaded connection with sealing ring is used between lens assembly and base, then connection security and sealing are improved, but device complexity increases
Solution Approach 1:
The threaded connection structure and sealing function are merged into a single integrated assembly. The lens assembly's threaded portion and the base's threaded structure work together with the sealing ring to simultaneously achieve mechanical fastening and sealing, eliminating the need for separate fastening and sealing components.
Solution Approach 2:
The threaded connection interface serves multiple functions: mechanical fastening, force distribution, positioning, and sealing support. This multi-functional design reduces the overall number of components needed while maintaining connection security and sealing performance.
Data Source
AI summary
An LED module having a base, a lens assembly, and a light source assembly. The lens assembly has an internal thread and the base has a matching external thread. The lens assembly and base are connected by the threads to form a closed accommodating space. A sealing ring is disposed at a portion between the thread connection of the base, lens assembly, and accommodating space. The light source assembly is in the accommodating space and at one side of the base. The lens assembly and the base are in threaded connection, providing an increased force bearing surface and even force bearing therebetween, resulting in a secure connection, good leakproofness, and convenient installation and removal. The sealing ring is disposed at the connection of the lens assembly and the base, allowing for an excellent sealing effect between the lens assembly and the base.