Light Source Module Lens Support Posts Prevent Adhesive Spread
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Solution Overview
Problem
In light source modules, the adhesive used during lens attachment can cause non-uniform light distribution and increase manufacturing costs and time due to the need for additional processes, leading to issues like speckles or mura in lighting apparatuses.
Innovation Solution
A light source module design featuring an optical device with a support structure that includes a protrusion to prevent adhesive spread, allowing for simultaneous mounting and attachment of the light source and optical device on a substrate using a single reflow process, thereby ensuring uniform light distribution and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lens is attached to a substrate using adhesive, then the optical device can be fixed in position, but the adhesive may spread and stick to the lens causing non-uniform light distribution
Solution Approach 1:
The support structure is divided into multiple protrusions that are spaced apart from each other. These segmented protrusions provide discrete attachment points that prevent adhesive from spreading across the entire first plane surface, thereby maintaining uniform light distribution while ensuring reliable fixing of the optical device
Solution Approach 2:
The protrusions act as intermediary elements between the support and the substrate. They provide a controlled interface for adhesive attachment, confining the adhesive to specific locations on the protrusions rather than allowing it to spread across the optical device's first plane surface
2Reliability
If a separate lens attachment process is added, then the optical device can be securely mounted, but manufacturing costs and time increase
Solution Approach 1:
The support structure integrates multiple functions into a single component: it provides mechanical support for the optical device, serves as an adhesive attachment surface through its protrusions, and prevents adhesive spread. This integration allows the optical device to be securely mounted without requiring a separate lens attachment process, thereby maintaining mounting security while improving manufacturing efficiency
Solution Approach 2:
The support structure is designed with multi-functionality, serving as both a mounting structure and an adhesive barrier. The protrusions simultaneously provide attachment points and prevent adhesive spread, eliminating the need for separate processes and reducing manufacturing complexity
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
This design prevents adhesive spread and ensures uniform light distribution, reducing manufacturing time and costs by eliminating the need for separate attachment processes, thus enhancing the optical uniformity and efficiency of light source modules.
Implementation Method 1
a lens having wide beam angle may be used to spread light laterally from a center portion across a large area using the refraction of light
Data Source
AI summary
A light source module includes a substrate, a light source mounted on the substrate, an optical device disposed on the light source, a support extending from a surface of the optical device facing the light source and fixed to the substrate, and a protrusion extending from and around a side surface of the support.