Curved LED Mount Surface for Single-Lens Field Curvature Correction
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Solution Overview
Problem
Existing optical apparatuses face difficulties in correcting field curvature when using a single lens with solid-state light sources, as the flat mount surface of printed boards makes it challenging to dispose light sources in a curved manner that matches the focal plane shape, leading to blurred images and reduced light-emitting efficiency.
Innovation Solution
An optical apparatus with a substrate having a curved mount surface that matches the focal plane shape of the lens, where solid-state light sources are positioned such that the line connecting their centers coincides with or is spaced from the focal plane, allowing for easy correction of field curvature by emitting parallel light, and incorporating insulating layers for heat dissipation and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat mount surface is used for mounting solid-state light sources, then the printed board structure is simple and easy to manufacture, but field curvature cannot be corrected and the light sources cannot be positioned to match the focal plane shape
Solution Approach 1:
The patent applies curvature to the mount surface by providing a curved surface (concave or convex) that matches the focal plane shape of the lens. This curved mount surface allows solid-state light sources to be positioned along a curved line, enabling correction of field curvature while maintaining a simple single-lens structure. The curved surface replaces the traditional flat printed board surface, directly addressing the positioning accuracy issue without complicating the manufacturing process.
2Manufacturing precision
If multiple lenses are used to correct field curvature, then the focal plane can be made substantially flat, but the device complexity increases and the total length of the optical system increases
Solution Approach 1:
The patent eliminates the need for multiple lenses by using a curved mount surface to position light sources along a curved line matching the focal plane. This single-lens configuration with curved light source positioning achieves field curvature correction without increasing device complexity or optical system length, directly resolving the contradiction between focal plane flatness and structural simplicity.
3Device complexity
If solid-state light sources are arranged in a concentrated manner, then field curvature can be corrected with a single lens, but the light-emitting area is reduced and heat generation increases
Solution Approach 1:
The curved mount surface allows light sources to be distributed along a curved line rather than concentrated in one location. This distributed arrangement on the curved surface maintains adequate spacing between light sources for heat dissipation while still achieving field curvature correction with a single lens, resolving the contradiction between structural simplicity and heat management.
4Manufacturing precision
If the mount surface is curved to match the focal plane, then field curvature is corrected and light is emitted as parallel light, but the printed board structure becomes more complex
Solution Approach 1:
The patent provides a curved surface that can be integrated into the headlight housing or lens assembly rather than requiring a curved printed board. This approach achieves light emission parallelism and field curvature correction while avoiding the manufacturing complexity of creating a curved printed board, as the curvature is provided by the housing or lens mount structure instead.
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 effectively corrects field curvature, ensuring that light from solid-state light sources is emitted as parallel light, improving image quality and light efficiency while allowing for easy assembly and heat management.
Implementation Method 1
The light emitted from the plurality of solid-state light sources toward the lens is refracted by the lens, and is then emitted from the emission surface of the lens toward the outside
Implementation Method 2
incorporating insulating layers for heat dissipation and electrical connectivity
Data Source
AI summary
An optical apparatus capable of correcting field curvature easily, a method for manufacturing the optical apparatus, and a headlight including the optical apparatus. A lens, a plurality of solid-state light sources, and a substrate on which the solid-state light sources are mounted. The substrate includes a base material, which is rigid, and a mount surface, which is formed on the base material in a curved surface shape that substantially matches a focal plane shape of the lens, and on which a circuit pattern is formed. The solid-state light sources are mounted on the mount surface, and the substrate is positioned with respect to the lens such that a position of a focal plane of the lens substantially coincides with emission surfaces of the solid-state light sources, and thus field curvature can be easily corrected.