Molded Lens Assembly for LED Fixtures
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Solution Overview
Problem
Existing LED lighting fixtures face challenges in efficiently directing and diffusing light while maintaining alignment and protection from environmental elements, particularly in outdoor settings where moisture and insects can damage components.
Innovation Solution
A lens assembly with a frame and molded lenses is coupled to a circuit board, featuring a gasket for sealing and mounting flanges for secure alignment, allowing for precise optical communication and protection from environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a lens assembly with frame and molded lenses is used, then light distribution is enhanced and alignment is maintained, but device complexity increases
Solution Approach 1:
The patent combines multiple components into an integrated lens assembly where lenses are molded directly to the frame structure. This merging of the lens and frame into a single molded unit simplifies assembly while maintaining precise alignment and effective light distribution control.
Solution Approach 2:
The lens assembly serves multiple functions simultaneously: it directs light distribution through the molded lenses, maintains alignment through the integrated frame structure, and provides environmental sealing when combined with the gasket. This multi-functionality reduces the need for separate components.
2Productivity
If gasket size is reduced to increase number of LED light sources, then productivity increases, but sealing effectiveness may worsen
Solution Approach 1:
The gasket is positioned specifically at the interface between the lens assembly frame and the circuit board housing, providing sealing effectiveness at the critical location where environmental protection is most needed. This localized sealing approach allows reduced gasket size while maintaining protection where it matters most, enabling more LED space.
Solution Approach 2:
The sealing function is segmented and integrated into the lens assembly frame structure itself, with the gasket forming part of the molded assembly. This segmentation allows the sealing function to be optimized independently from the overall assembly size, enabling smaller gasket dimensions that fit tighter spaces around multiple LEDs.
3Manufacturing precision
If lens assembly is coupled to circuit board with mounting flanges, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The mounting flanges are merged into the lens assembly frame as an integrated molded feature rather than a separate component. This combination provides precise alignment functionality while simplifying the overall device structure by eliminating the need for separate mounting brackets or alignment mechanisms.
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 solution enhances light distribution, increases the number of LED light sources by reducing gasket size, and maintains proper alignment, thereby improving the overall efficiency and durability of LED lighting fixtures in outdoor environments.
Implementation Method 1
each of the plurality of lenses is in optical communication with a corresponding LED light source
Data Source
AI summary
A lighting fixture is provided. The lighting fixture may include one or more circuit boards having a plurality of LED light sources. The lighting fixture may further include one or more lens assemblies coupleable to the one or more circuit boards. The one or more lens assemblies may include a frame defining a plurality of openings. The one or more lens assemblies may further include a plurality of lenses molded to the frame. The plurality of lenses may be molded to the frame such that each of the plurality of lenses is at least partially positioned within a corresponding opening of the plurality of openings defined by the frame.