LED Spotlight Lens Plate with Central Focus and Peripheral Diffusion
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Solution Overview
Problem
Current spotlight devices have complex structures and high costs, making them less adopted, and there is a need for a simpler design that also considers heat dissipation and assembly factors.
Innovation Solution
A LED apparatus with a metal cup for heat dissipation, a lens plate for focused light beams, and a driver plate, featuring a detachable lens system and cost-effective manufacturing methods such as using Polycarbonate materials and elastic metal pins for easy assembly and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If traditional spotlight devices are used to achieve focused light beam, then spotlight function is achieved, but structure becomes complicated and cost increases
Solution Approach 1:
The lens plate is divided into a central lens region and a peripheral lens region, each with different optical functions. The central lens focuses light to create a spotlight beam, while the peripheral lens provides diffuse lighting. This segmentation allows the device to achieve spotlight function without requiring complex additional optical components.
Solution Approach 2:
The lens plate serves multiple functions simultaneously: it acts as both a focusing element for spotlight and a diffusing element for ambient light. The cup body integrates heat dissipation, structural support, and optical housing functions. This multi-functionality reduces the number of separate components needed, simplifying the overall structure.
2Illumination intensity
If traditional spotlight devices are used, then spotlight function is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines the lens and the housing into a single integrated lens plate component that can be molded as one piece. The cup body is also designed as a single molded piece that integrates structural support and heat dissipation features. This merging of functions into fewer components reduces manufacturing steps and assembly costs.
Solution Approach 2:
The invention uses standard LED modules with common specifications, allowing for easier procurement and replacement. The lens plate can be manufactured using conventional molding techniques with adjustable parameters to produce different beam patterns, reducing the need for custom optical components.
3Illumination intensity
If LED modules are used for high intensity light, then illumination is improved, but heat generation increases requiring complex heat dissipation
Solution Approach 1:
The cup body itself serves as the heat dissipation structure, utilizing its own mass and surface area to conduct and radiate heat away from the LED modules. The integrated design means the structural component also performs the heat management function, eliminating the need for separate heat sinks or active cooling systems.
Solution Approach 2:
The patent employs materials with high thermal conductivity for the cup body and base plate to efficiently conduct heat away from the LED modules. The combination of these thermally conductive materials with the optical lens material creates a composite structure that simultaneously manages heat and light.
4Ease of manufacture
If fixed lens system is used, then manufacturing is simplified, but adaptability for different light beam characteristics is reduced
Solution Approach 1:
The lens plate is designed to be replaceable, allowing the optical characteristics of the spotlight to be dynamically adjusted by swapping different lens plates with varying central lens configurations. This provides adaptability for different beam patterns while maintaining simple manufacturing of individual lens plate components.
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 solution provides a cost-effective, easily assembled LED spotlight with improved heat dissipation and adjustable light beam characteristics, enhancing both functionality and affordability.
Implementation Method 1
The metal cup has a bottom surface attaching to the back side of the base plate for heat dissipation for heat generated by the LED plate
Implementation Method 2
The central lens guiding light from the LED modules for form a focus light beam for spotlight function
Data Source
AI summary
A LED apparatus has a LED plate, a lens plate, a cup body, a driver plate and two metal pins. The lens plate has a central lens and a plurality of micro optical structures. The cup body has a dome portion, a tube portion and a bottom portion. The dome portion and the tube portion are manufactured together as a single body. A portion of light emitting from the LED plate runs through the central lens of the lens plate to form a focus light beam and another portion of light emitting from the LED modules running through the plurality of micro optical structures to form soft light. Two input terminals of the driver plate are inserted into the two metal pins.