Press-Fit LED Cover Structure for Faster Lighting Assembly
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Solution Overview
Problem
Existing lighting devices face issues with LED damage during installation, prolonged installation times due to manual sponge attachment, and reduced illumination intensity and longevity due to sponge light absorption and vulcanization.
Innovation Solution
A lighting device design featuring a transparent or translucent case with a press-fitted cover made of rigid material to prevent LED contact and simplify installation, using a substrate with integrated light emitters and a housing to maintain protection and illumination efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sponges are used to surround and protect LEDs, then LED damage due to contact with case is prevented, but installation time increases due to manual positioning and attachment
Solution Approach 1:
The protection function is segmented from the sponge material and integrated into the rigid cover structure. The cover includes integrated protection walls that surround the LEDs, eliminating the need for separate sponge components and their manual attachment processes.
Solution Approach 2:
The protection walls are merged with the rigid cover as an integrated structure. The cover and protection walls form a single component that provides both structural support and LED protection, replacing the previously separate sponge elements.
2Reliability
If sponges are used for light shielding, then LED contact protection is improved, but illumination intensity decreases due to light absorption
Solution Approach 1:
The protective function of the sponges is copied and implemented through the rigid cover's integrated protection walls. This allows the protective function to be replicated without using light-absorbing sponge material, thereby maintaining illumination intensity.
Solution Approach 2:
The material parameter changes from light-absorbing sponge to light-transmissive rigid cover material. This parameter change maintains LED protection while eliminating the light absorption issue, preserving illumination intensity.
3Reliability
If vulcanized sponges are used for LED protection, then initial protection is provided, but long-term usage causes LED chip corrosion and reduced brightness
Solution Approach 1:
The sponge material is replaced with a durable rigid cover structure designed for long-term use. The rigid cover does not degrade over time like vulcanized sponges, providing sustained protection without causing LED corrosion throughout the product's lifespan.
Solution Approach 2:
The rigid cover is made from materials that combine protective properties with long-term stability. The composite structure provides both immediate protection and long-term durability, preventing the degradation issues associated with vulcanized sponge materials.
4Manufacturing precision
If manual positioning and attachment of sponges is performed, then precise LED protection is achieved, but productivity decreases
Solution Approach 1:
The protection function is segmented into integrated protection walls formed as part of the rigid cover. This eliminates the need for separate positioning and attachment operations, improving assembly speed while maintaining protection precision through the integrated design.
Solution Approach 2:
The protection walls are pre-formed as an integral part of the rigid cover during cover manufacturing. This preliminary action eliminates the need for subsequent manual positioning and attachment steps, improving productivity while ensuring precise protection alignment.
Data Source
AI summary
A lighting device includes: a case made from a material allowing light to penetrate therethrough and having a cylinder shape with a closed bottom; a substrate including a light emitter configured to emit light; and a cover made from a rigid material, press-fitted and installed in the substrate so as to cover the light emitter, and installed inside the case together with the substrate.