Light Transmissive Cover with Convex Concave Lens for LED Arrays
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Solution Overview
Problem
The existing methods for manufacturing light emitting devices using LEDs are costly and inefficient due to complex lens formation processes, leading to non-uniform light distribution and increased manufacturing costs, as well as a spot phenomenon caused by individual lens formation on each LED chip, which affects illumination intensity and color temperature consistency.
Innovation Solution
A light emitting device design featuring a substrate with mounted LED chips and a light-transmissive cover with convex and concave portions to uniformly cover multiple LED chips, reducing manufacturing time and cost, and using a phosphor material in a resin packaging unit to convert light wavelengths, while optimizing light radiation angles and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If individual lenses are formed on each LED chip through dispensing, then light distribution can be adjusted, but the manufacturing process becomes complicated and unit manufacturing cost increases
Solution Approach 1:
The patent merges multiple individual lens formation processes into a single batch processing step. A mold with multiple cavities is used to simultaneously form lenses on multiple LED chips in one operation, thereby simplifying the manufacturing process while maintaining the ability to adjust light distribution for each chip.
Solution Approach 2:
The invention creates a universal mold structure that can serve multiple functions: it acts as both a lens formation tool and a alignment guide for LED chips. The mold includes positioning structures that automatically align multiple LED chips, eliminating the need for separate alignment processes and reducing overall manufacturing complexity.
2Illumination intensity
If individual lenses are formed on each LED chip, then light distribution can be optimized, but manufacturing time increases due to sequential processing
Solution Approach 1:
The patent combines multiple lens formation operations into a single batch processing step using a multi-cavity mold. This allows simultaneous formation of lenses on multiple LED chips, dramatically increasing manufacturing throughput while maintaining optimized light distribution for each individual chip.
Solution Approach 2:
The mold is pre-configured with multiple cavities and positioning structures before the manufacturing process begins. This preliminary preparation enables all LED chips to be processed simultaneously in the correct positions, eliminating sequential processing delays and improving overall manufacturing efficiency.
3Ease of manufacture
If lenses are formed with fixed configurations through dispensing, then manufacturing is simplified, but the shape of the lens cannot be changed to suit different light emitting device characteristics
Solution Approach 1:
The patent implements local quality by providing different lens configurations in different cavities of the same mold. Each cavity can be designed with specific lens shapes, sizes, and optical properties tailored to the characteristics of the LED chips it processes, while maintaining ease of manufacture through the standardized mold structure.
Solution Approach 2:
The mold is segmented into multiple independent cavities, each capable of forming lenses with different configurations. This segmentation allows the system to maintain simple standardized manufacturing processes while producing diverse lens shapes that adapt to different LED chip characteristics and light emitting device requirements.
4Temperature
If phosphors are applied to respective LED chips individually, then color temperature can be adjusted per chip, but deviation of color temperature between chips increases
Solution Approach 1:
The patent merges the phosphor application process into the batch processing workflow, where phosphors are applied uniformly across multiple LED chips simultaneously. This ensures consistent color temperature across all chips while maintaining the ability to adjust overall color temperature characteristics for the entire array.
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 reduces manufacturing costs and time, enhances light uniformity, minimizes the spot phenomenon, and improves light efficiency by allowing for a more flexible lens shape and reduced silicon usage, while maintaining consistent color temperature and efficient light distribution.
Implementation Method 1
a light-transmissive cover formed to be upwardly convex, having one or more localized concave portions, and installed on the substrate to cover at least two of the plurality of light emitting elements together
Data Source
AI summary
A light emitting device includes: a substrate having a bar shape; a plurality of light emitting elements separately mounted in a lengthwise direction of the substrate on an upper surface of the substrate; and a light-transmissive cover formed to be upwardly convex, having one or more localized concave portions, and installed on the substrate to cover at least two of the plurality of light emitting elements together.