LED Light Guide Cover Structure for Stable Optical Positioning
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Solution Overview
Problem
Existing light-emitting devices with LEDs face challenges in maintaining a constant distance between the light-emitting element and the light guide, leading to size and weight issues, as well as quality variations due to displacement of the light guide by gravity and external forces.
Innovation Solution
A light-emitting device design featuring a board with a light-emitting element, a support member, and a cover with protrusions that interlock to hold the board in place, preventing the light guide from moving and maintaining a consistent distance between the light-emitting element and the light guide, while reducing the overall size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the board and lens are sandwiched and held using the case and connector, then the lens can be held in position, but the lens must be made relatively strong which makes it large in size, causing the light-emitting device to become large in size and weight
Solution Approach 1:
The support member is divided into a case and a cover that can be assembled together. The case has engagement protrusions that fit into engagement recesses in the cover, creating a segmented structure that holds the board and lens without requiring a single large enclosing case, thereby reducing overall device size and weight while maintaining positioning stability.
Solution Approach 2:
The board is placed inside the chamber formed by the case and cover assembly. The engagement protrusions and recesses are nested within each other to secure the board and lens in position. This nested arrangement allows compact positioning of components without requiring additional external fixing structures, reducing the device footprint and weight.
2Manufacturing precision
If the end face of the light guide body is held in abutment against the protrusion to position it vertically, then the light guide body can be positioned, but it tends to move with respect to the tubular portion by gravity, increasing the distance between the light-emitting element and the light guide body
Solution Approach 1:
The light guide body is extracted from the tubular portion during assembly and then secured by the engagement mechanism between the case and cover. The engagement protrusions and recesses are specifically designed to clamp the light guide body in position, preventing it from moving due to gravity. This extraction and re-securing approach allows precise positioning while maintaining stability during operation.
Solution Approach 2:
The engagement protrusions and recesses are pre-formed in the case and cover respectively, creating a predetermined positioning mechanism. When the cover is assembled onto the case, this pre-designed engagement structure automatically secures the light guide body at the correct position, preventing gravitational movement before the device is even operational.
3Stability of the object's composition
If a large case and connector structure is used to hold the board and lens, then positioning stability is achieved, but the device complexity increases
Solution Approach 1:
The support member, positioning mechanism, and protective enclosure are merged into a single integrated assembly consisting of the case and cover. The engagement protrusions and recesses serve dual purposes: they secure the board in position and simultaneously form the structural enclosure. This merging of functions reduces the number of separate components needed, simplifying the overall device structure while maintaining positioning stability.
Data Source
AI summary
A light-emitting device includes a board, a light-emitting element mounted on a surface of the board, a support member on which the board is placed, and a cover having a plate shaped main cover body covering the light-emitting element and a tubular portion which receives a light guide body that guides light emitted from the light-emitting element. The main cover body includes a base, a protrusion protruding from the base toward the board, and a ridge disposed on a protruded end of the protrusion. A step is formed by the protrusion and the ridge, and the protrusion and the ridge extend in a same direction along the base.