Bat-wing Lens Design with Multi-die LED
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing batwing optical emitters using two separate lenses are costly, difficult to manufacture, and unsuitable for multiple LED dies, leading to non-uniform light output and alignment issues, which affect the desired beam pattern and efficiency.
Innovation Solution
A single molded lens with a batwing surface is directly attached to the LED dies on a package substrate, centered around the focus of a parabolic curve, eliminating the need for a second lens and improving light extraction efficiency while allowing for multiple LED dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two separate lenses are used to achieve batwing beam pattern, then the desired beam pattern can be obtained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines two separate lenses into a single integrated molded lens with a batwing surface. This single lens integrates the optical functions that previously required two separate components, thereby reducing manufacturing complexity and assembly steps while maintaining the desired batwing beam pattern through the specially designed batwing surface geometry
Solution Approach 2:
The patent segments the LED light source into multiple individual LED dies arranged in an array. Each LED die is independently positioned and contributes to the overall light output, allowing the single molded lens with batwing surface to effectively shape the combined light from multiple sources into the desired batwing beam pattern
2Manufacturing precision
If two separate lenses are used, then beam pattern can be controlled, but alignment difficulty increases
Solution Approach 1:
By merging the alignment function into a single molded lens that is directly formed over the LED die array, the patent eliminates the need for complex alignment procedures between two separate lenses. The single lens is positioned and secured in one operation, significantly improving ease of manufacture while maintaining precise beam pattern control through the batwing surface design
3Ease of manufacture
If single molded lens is used with multiple LED dies, then manufacturing cost reduces, but light output uniformity may affect
Solution Approach 1:
The patent applies local quality by designing the batwing surface with specific geometric features including a valley region and peak regions. The valley portion is positioned to receive light from multiple LED dies and redirect it at controlled angles, while the peak regions shape the light distribution to achieve uniform output. This localized surface geometry optimization ensures uniform light output across the beam pattern while maintaining the cost-effective single-lens structure
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 reduces manufacturing complexity and cost, enhances light output uniformity, and maintains the desired batwing beam pattern across various angles, making it suitable for multiple LED configurations.
Implementation Method 1
a molded lens having a batwing surface... The batwing surface is formed by rotating an arc about a line at an end of the arc parallel to a conjugate axis of a curve
Implementation Method 2
The optical emitter outputs a batwing beam pattern through the molded lens
Data Source
AI summary
A batwing beam is produced from an optical emitter having a primary LED lens over a number of LED dies on a package substrate. The LED lens includes a batwing surface formed by rotating a parabolic arc about an end of the parabolic arc over a center of the optical emitter. A center of each of the LED dies is mounted to the package substrate about the focus of a parabola whose arc forms the batwing surface, for example, between about 0.5 to 1.5 of a focal distance from the vertex of the parabola. The batwing surface reflects light from the number of LED dies through total internal reflection (TIR) or through a reflectivity gel coating.