IR LED Lens Molding for Iris Recognition
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Solution Overview
Problem
Current IR LED-based light sources for iris recognition systems are expensive and difficult to manufacture, with complex processes that hinder mass production due to the need for separate molding and bonding of supporting structures and lenses, which are ineffective for light focusing.
Innovation Solution
A light-emitting device with a molded body and lens configuration that forms a sealed chamber to enclose the light-emitting element, using a vacuum or special gas to protect it and provide the necessary optical refractive index for focused light emission, allowing for efficient manufacturing through integrated molding and bonding of metal leads and lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate molding and bonding of supporting structures and lenses is used, then manufacturing precision can be maintained, but device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent combines the supporting structure and lens into a single integrated component that is molded as one piece. This eliminates the need for separate molding and bonding processes, reducing manufacturing complexity while maintaining precision through unified design and single-step fabrication.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it provides mechanical support, structural stability, and optical focusing through the lens. This multi-functionality reduces the number of separate components needed and simplifies the overall device architecture.
2Reliability
If separate molding and bonding processes are used, then component quality can be controlled, but productivity decreases due to complex manufacturing steps
Solution Approach 1:
By merging the supporting structure and lens into a single molded component, the manufacturing process is streamlined into fewer steps. This integration maintains component quality through precise molding while significantly improving productivity by eliminating repetitive bonding operations.
Solution Approach 2:
The lens is pre-integrated into the supporting structure during the molding process itself, rather than being added later through bonding. This preliminary integration ensures quality control is built into the fabrication process and enables faster production cycles.
3Reliability
If conventional LED packaging with sealing members is used, then LED protection is achieved, but light focusing capability is lost due to refractive index mismatch
Solution Approach 1:
The patent changes the refractive index parameter of the lens material to match or complement the LED emission characteristics. This optimization enables effective light focusing while the integrated structure maintains LED protection, resolving the contradiction between protection and focusing capability.
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 enables cost-effective and scalable production of light-emitting devices with improved light focusing capabilities, reducing contamination risks during manufacturing and enabling direct soldering onto mainboards, thus simplifying integration into compact devices like smartphones.
Implementation Method 1
The sealed chamber has a different optical refractive index from the surrounding materials and is necessary to obtain the desired beam angle
Implementation Method 2
The sealed chamber is a vacuum chamber or contains air or special gas (e.g., dinitrogen, argon, inert gas)
Data Source
AI summary
A light-emitting device and a method of manufacturing the device are disclosed in this invention. The light-emitting device includes a molded body having metal leads and a plane surface for mounting a light-emitting element. The light-emitting device also includes a lens having one central portion, one edge portion surrounding the central portion, and one base portion supporting the central portion and the edge portion. The central portion has a dome-shaped top surface. The edge portion has one inner top surface and one outer top surface, and the inner top surface of the edge portion connects with the dome-shaped top surface of the central portion to form a valley-shaped groove. The base portion is attached onto the molded body to form a sealed chamber to enclose the light-emitting element.