Segmented Optical Lens Assembly for LED High Bay Light Manufacturing
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Solution Overview
Problem
The existing one-piece injection molding structure of optical lenses in LED high bay lights increases manufacturing complexity and costs due to the requirement for long lenses, posing challenges in mold creation and part production.
Innovation Solution
The LED high bay light employs a strip-shaped optical lens set with multiple sections, connected by stepped spigots, which reduces mold complexity and manufacturing costs, and features a screw-based connection to a driving circuit board for improved assembly and dust prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece injection molding structure is used for the optical lens, then the lens can be manufactured as a single component, but the mold complexity and manufacturing cost increase significantly when the lens length increases
Solution Approach 1:
The optical lens is divided into multiple sections along its length direction, with each section being a separate injection-molded component. This segmentation allows each mold to be smaller and simpler, reducing mold manufacturing cost and complexity while enabling the production of longer overall lens assemblies through concatenation of multiple sections.
2Ease of manufacture
If a one-piece injection molding structure is used for the optical lens, then the lens structure is simple, but the difficulty and cost of making the mold increase greatly when the lens length increases
Solution Approach 1:
The optical lens is divided into multiple sections along its length direction, with each section being a separate injection-molded component. This segmentation allows each mold to be smaller and simpler, reducing mold manufacturing cost and complexity while enabling the production of longer overall lens assemblies through concatenation of multiple sections.
3Reliability
If multiple strip-shaped optical lenses are connected through stepped spigots, then position shifting is prevented and reliability is improved, but the device complexity increases
Solution Approach 1:
The stepped spigot structure enables self-alignment and self-location of adjacent optical lens sections during assembly. The stepped geometry provides automatic positioning features that guide the sections into correct relative positions without requiring additional alignment mechanisms or complex assembly procedures.
Solution Approach 2:
The connection structure integrates multiple functions into the spigot feature itself: mechanical joining of sections, positional alignment, and sealing against dust ingress. This merging of functions reduces the need for separate components while maintaining reliability.
4Temperature
If space is left between LED illuminant engines, then heat dispersion through convection is improved, but the overall device length increases
Solution Approach 1:
The design provides localized spacing between LED illuminant engines specifically at heat-generating regions to enable convective heat dissipation. This targeted approach to thermal management addresses heat accumulation problems without requiring uniform spacing throughout the entire fixture, thus minimizing the impact on overall length.
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 simplifies mold creation, reduces manufacturing costs, enhances product reliability by preventing position shifting and dust ingress, and improves heat dispersion through convection, resulting in a more efficient and cost-effective lighting solution.
Implementation Method 1
two adjacent strip-shaped optical lenses are connected to each other through the mutual cooperation of the stepped spigots arranged oppositely
Implementation Method 2
an LED strip-shaped illuminant comprises a plurality of LED lamp beads and an LED strip-shaped driving circuit board that drives the LED lamp beads to operate
Implementation Method 3
an optical lens set covering the LED strip-shaped illuminant; the optical lens set comprises a plurality of strip-shaped optical lenses arranged conterminously
Implementation Method 4
leaving a space between two LED illuminant engines, allowing heat dispersion through convection to be realized during operation of the LED high bay light
Data Source
AI summary
An LED high bay light comprises a plurality of LED illuminant engines arranged abreast and alternately; each of the LED illuminant engine comprises an LED strip-shaped illuminant and an optical lens set covering the LED strip-shaped illuminant; the optical lens set comprises a plurality of strip-shaped optical lenses arranged conterminously; and two adjacent strip-shaped optical lenses are connected to each other through a mutual cooperation of the stepped spigots arranged oppositely. Each illuminant engine thereof adopts a structure of strip-shaped optical lens set with multiple sections, greatly reducing the difficulty in making molds and the cost for manufacturing parts.