Industrial Lighting Lens Structure for Lower-Cost Light Distribution
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Solution Overview
Problem
Current mining lamps with spherical lenses require extended holding pressure times for injection molding, leading to high manufacturing costs and complex assembly processes, which affect light-emitting angle and brightness.
Innovation Solution
A high luminous-efficacy industrial lighting device with an asymmetrical lens design featuring a central portion and side portions, including light entrance, reflection, and exit surfaces, securely fixed to a base with connecting surfaces, and flexible assembly through curved arms and a housing design, allowing for improved light concentration and uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spherical lenses are used with extended holding pressure time for injection molding, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The lens is divided into multiple segments with different curvatures (first curvature in central region, second curvature in peripheral region). This segmentation allows each region to be optimized independently, achieving precise light control without requiring extended holding pressure time for the entire lens, thus reducing manufacturing cost while maintaining precision.
Solution Approach 2:
Different regions of the lens are assigned different optical properties (curvatures). The central region has one curvature optimized for direct light transmission, while the peripheral region has another curvature optimized for light reflection. This local quality differentiation achieves overall optical precision without uniformly increasing manufacturing complexity and cost across the entire lens.
2Manufacturing precision
If spherical lenses are used with complex assembly processes, then manufacturing precision is maintained, but device complexity increases
Solution Approach 1:
The lens is integrated with the housing as a unified structure, where the lens serves dual functions: transmitting light through the central region and reflecting light through the peripheral region. This merging eliminates the need for separate spherical lens components and complex assembly processes, reducing device complexity while maintaining manufacturing precision.
Solution Approach 2:
The lens structure performs multiple functions simultaneously: it acts as both a transmission window and a reflective surface, while also providing structural support and light direction control. This multi-functionality reduces the number of separate components needed, simplifying the assembly process without compromising precision.
3Ease of manufacture
If insufficient holding pressure time is used during injection molding, then manufacturing cost is reduced, but light-emitting angle and brightness are compromised
Solution Approach 1:
The lens is segmented into regions with different curvatures that work together to control light distribution. The first curvature region optimizes light transmission angle while the second curvature region optimizes light reflection angle. This segmentation allows the use of reduced holding pressure time during injection molding without compromising overall light-emitting performance, as each region independently contributes to the desired light distribution.
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 device enhances luminous efficacy and brightness by reducing optical loss and manufacturing costs while providing flexible assembly and enhanced heat dissipation, with adjustable light-emitting angles for various applications.
Implementation Method 1
Each of the side portions includes a light entrance surface, a reflection surface, and a light exit surface. The light emitted from the light source board passes through the light entrance surface, is then reflected by the reflection surface, and exits through the light exit surface.
Data Source
AI summary
A high luminous-efficacy industrial lighting device includes at least one lighting module. The lighting module includes a base, a light source board and a lens. The light source board is disposed on the base. The lens is disposed on the base and covers the light source board. The lens includes an optical module including a central portion and two side portions respectively disposed on the two sides of the central portion, such that an accommodation space is formed between the central portion and the side portions. The light source board is disposed within the accommodation space and faces the central portion.