Cylindrical Lens Array for Uniform UV Curing
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Solution Overview
Problem
Conventional light emitting devices with uniform cylindrical lenses often result in incomplete curing of ink or resin, as intense ultraviolet light primarily cures the surface while leaving the interior insufficiently cured, necessitating a device with a gradually changing light intensity distribution.
Innovation Solution
A light emitting device featuring a substrate with multiple rows of light emitting elements and a light-transmissive member comprising cylindrical lenses of varying heights, where the second cylindrical lens portion at the center has the greatest height, allowing for a gradual change in light intensity distribution along the arrangement direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform cylindrical lenses are used in the light-transmissive member, then the device structure is simple and easy to manufacture, but the light intensity distribution becomes too intense at the center, causing only surface curing of ink or resin while leaving the interior insufficiently cured
Solution Approach 1:
The patent applies local quality by making the cylindrical lenses have different heights based on their position in the array. Specifically, the height of each cylindrical lens is determined by a quadratic function of its position, creating a parabolic height distribution. This means lenses at the edges are taller while the central lenses are shorter, thereby locally adjusting the light transmission properties to achieve a uniform light intensity distribution across the entire illuminated area, solving the surface-only curing problem
2Productivity
If intense ultraviolet light is used for curing, then the curing speed is fast and productivity is high, but the light intensity distribution becomes non-uniform, causing surface portion to be cured while interior portion remains insufficiently cured
Solution Approach 1:
The patent applies parameter changes by modifying the height parameter of the cylindrical lenses according to their positional coordinates. The height h of each lens is defined by the formula h = a - b(x² + y²), where (x, y) are the positional coordinates and a, b are constants. This parameter variation creates a parabolic light intensity distribution that compensates for the natural Gaussian distribution of LED light, enabling uniform curing across the entire surface while maintaining high curing speed through the use of intense ultraviolet light
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 configuration ensures more uniform curing by gradually increasing light intensity, effectively curing both the surface and interior of ink or resin, enhancing the curing process compared to devices with uniformly heighted lenses.
Implementation Method 1
a light-transmissive member including a cylindrical lens portion having an array of three or more cylindrical lenses arranged parallel to each other
Implementation Method 2
a plurality of light emitting elements arranged in three or more rows on the substrate
Data Source
AI summary
A light emitting device includes a substrate, a plurality of light emitting elements arranged in three or more rows on the substrate, and a light-transmissive member including a cylindrical lens portion having an array of three or more cylindrical lenses arranged parallel to each other along the rows of the light emitting elements so that each of the cylindrical lenses is on one of the three or more rows of light emitting elements. The rows of the light emitting elements are arranged with substantially uniform intervals. The cylindrical lens portion includes first cylindrical lens portions including at least cylindrical lenses at outermost sides of the array, and a second cylindrical lens portion arranged at an inner side of the first cylindrical lens portions and having a height greatest in the cylindrical lens portion.