Lens Flange Recesses for Mold Adhesion in LED Arrays
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Solution Overview
Problem
Existing light source devices and lens structures face challenges in achieving good adhesion between the support part and the lens, which affects the manufacturing process and optical performance.
Innovation Solution
A light source device and lens structure are designed with a support part made of a light-shielding material that supports the flange part of the lens, and they are molded in one body through double-shot molding, with the flange part featuring a recess on its surface to enhance adhesion during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flange part is molded directly without recesses, then the molding process is simpler, but the adhesion between the lens and support part is insufficient
Solution Approach 1:
The flange part incorporates recesses that create a porous or cavity-rich structure on its surface. These recesses increase the surface area and provide mechanical interlocking features that significantly improve adhesion between the lens and the support part during the molding process, while the recesses are designed to be minimal in size and number to avoid excessive complexity
Solution Approach 2:
The recesses are pre-formed in the flange part before the final molding operation. This preliminary structuring of the flange part ensures that when the support part is molded over it, the adhesion occurs automatically through the pre-prepared recesses, eliminating the need for additional adhesion-promoting steps
2Ease of manufacture
If recesses are added to the flange part to improve adhesion, then the lens separates easier from the mold, but the recesses may impact optical performance
Solution Approach 1:
The recesses are localized to specific areas of the flange part that are non-optical regions. By confining the recesses to the flange portion rather than the optically functional surfaces, the design improves adhesion and mold separation while maintaining the precision and quality of the optical surfaces unaffected
Solution Approach 2:
The lens structure is segmented into distinct functional zones: the optically functional part with smooth precision surfaces and the flange part with recesses for adhesion. This segmentation allows each part to optimize its function without compromising the other - optical performance in the lens portion and adhesion in the flange portion
3Adaptability or versatility
If multiple core portions are moved independently during manufacturing, then the molding flexibility is increased, but the number of manufacturing steps increases
Solution Approach 1:
The mold structure is designed to combine multiple core portions into a unified or coordinated system that moves together or in a synchronized manner. This merging approach maintains the flexibility needed for complex lens geometries while reducing the number of independent movement steps required during manufacturing
Data Source
AI summary
A light source device includes: a light source having an upper surface including a light-emitting surface, the light source including a plurality of light-emitting parts arranged in a two-dimensional array; a lens located above and spaced apart from the light-emitting surface of the light source, wherein the lens includes an optically functional part, and a flange part located along an outer periphery of the optically functional part; and a support part formed of a light-shielding member and configured to support at least the flange part of the lens.