Moldable Lens with Blocking Protrusion for LED Module Protection
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Solution Overview
Problem
Current LED advertising board backlight modules face damage from hot liquid plastic in low-pressure molding processes and require complex, costly assembly methods to prevent optical part damage and ensure waterproofing.
Innovation Solution
A lens design featuring a mechanical part with a blocking protrusion parallel to the optical axis, which prevents hot liquid glue from reaching the optical part during low-pressure molding, while also being made from materials like polycarbonate or silicon dioxide to maintain optical quality and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If low pressure molding technology is used to package LED modules, then integration and appearance are improved, but the optical parts are damaged by hot liquid plastic
Solution Approach 1:
The lens is divided into two functional parts: an optical part for light transmission and a mechanical part with a blocking protrusion for protection. The blocking protrusion extends into the liquid plastic and creates a barrier that prevents hot liquid plastic from contacting the optical part, thus segmenting the protective function from the optical function.
Solution Approach 2:
The blocking protrusion acts as an intermediary barrier between the hot liquid plastic and the optical part. It is positioned in the liquid plastic during molding and prevents direct contact between the harmful hot liquid plastic and the sensitive optical part, thereby protecting the optical part while allowing the molding process to proceed.
2Manufacturing precision
If additional lens mounting and liquid plastic perfusion are performed separately, then optical properties are improved, but the process complexity and cost increase
Solution Approach 1:
The lens is designed as an integrated component that combines both optical functionality and mechanical protection features. The blocking protrusion is formed as part of the lens structure itself, allowing the lens to be mounted and the liquid plastic to be perfused in a single unified process, thereby reducing process complexity and cost.
3Object-affected harmful factors
If two covers are used to form a cavity for liquid glue perfusion, then lens protection is improved, but component count and assembly complexity increase
Solution Approach 1:
The protective function previously requiring separate covers and assembly steps is now integrated into the lens structure itself. The blocking protrusion on the lens creates the necessary barrier against liquid plastic without requiring additional protective covers or complex assembly procedures.
Solution Approach 2:
The lens serves multiple functions: it provides optical transmission, structural support, and protection against liquid plastic. The blocking protrusion enables the lens to perform the protective function that previously required separate components, making the lens a multi-functional element in the LED module.
Data Source
AI summary
A lens configured to a lighting device, comprising an optical part (1) and a mechanical part (2) surrounding the optical part (1), wherein, the mechanical part (2) comprises a blocking protrusion (3) protruding in a direction parallel to the optical axis (4) of the lens, surrounding the optical part (1) and spaced apart from the optical part (1). This type of lens can effectively prevent the optical part from being damaged, for example, in a low pressure molding process, by a hot liquid glue, improve the yield of the lighting device, and have fine waterproof ability at the same time. Also disclosed is a lighting device having this type of lens, and the lighting device has beautiful appearance and fine waterproof effect. A method configured to make this lighting device is also disclosed.