LED Array Lens Layout for Dense Packing and Light Transmission
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Solution Overview
Problem
Conventional light-emitting assemblies with LED arrays face limitations in achieving optimized packaging and lens construction for high-light output and transmission in a compact spatial package, which restricts their end-use applications and are not cost-effective in terms of labor and raw materials.
Innovation Solution
The arrangement of LED dies on a common substrate with a highly-reflective material and individual optical lenses made of silicone with phosphor particles, where each lens is sized and shaped to promote optimal light transmission, and fillet segments are used between adjacent lenses to prevent overlap, allowing for efficient packing density and light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pre-formed dome-shaped lenses are used to protect LED dies and facilitate light emission, then the LED array provides focused light emission and physical protection, but the packaging density is reduced and the spatial package size increases
Solution Approach 1:
The patent divides the lens system into individual lenses for each LED die rather than using a single pre-formed dome-shaped lens covering multiple dies. This segmentation allows each lens to be optimally sized for its specific LED die, reducing overall package volume while maintaining protection and light emission functionality.
Solution Approach 2:
Each LED die is provided with its own customized lens with specific optical properties tailored to that die's characteristics. This local optimization allows for better light extraction and directionality from each die while minimizing the total space required for the lens array.
2Reliability
If conventional lens-forming material is disposed over LED dies and shaped by molding techniques, then the lens provides protection and light emission facilitation, but the manufacturing complexity and labor costs increase
Solution Approach 1:
The lens-forming material is prepared and positioned before the final molding step, with pre-defined regions allocated to each LED die. This preliminary arrangement simplifies the molding process by eliminating complex multi-step shaping operations and reduces labor requirements.
Solution Approach 2:
The patent combines multiple functions into a single lens structure: protection of LED dies, light emission facilitation, and optical focusing are all achieved through the integrated lens-forming material that covers multiple dies in one continuous layer, simplifying manufacturing.
3Illumination intensity
If LED dies are arranged with larger spacing to accommodate conventional lenses, then each die has sufficient space for light emission, but the packaging density and light output per unit area are reduced
Solution Approach 1:
The patent optimizes the vertical dimension of the lens structure to achieve better light extraction and directionality, allowing for reduced horizontal spacing between LED dies. By controlling light propagation in the vertical dimension through lens design, closer packing in the horizontal plane becomes feasible without compromising light emission quality.
Solution Approach 2:
The optical parameters of the lenses (curvature, refractive index, thickness) are optimized to enhance light extraction efficiency from each LED die. This allows for tighter packing of dies while maintaining or improving overall light output per unit area, as each die's light is more effectively directed and extracted.
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 results in a compact, high-light output, and cost-effective light-emitting assembly with optimized LED die spatial arrangement and lens construction, enhancing light transmission efficiency compared to conventional assemblies.
Implementation Method 1
The lens is formed from silicone that comprises phosphor particles dispersed therein
Implementation Method 2
LED dies arranged in a fixed position relative to one another on a common substrate with a highly-reflective material
Data Source
AI summary
Light emitting assemblies comprise a plurality of Light Emitting Diode (LED) dies arranged and attached to common substrate to form an LED array having a desired optimum packing density. The LED dies are wired to one another and are attached to landing pads on the substrate for receiving power from an external electrical source via an interconnect device. The assembly comprises a lens structure, wherein each LED die comprises an optical lens disposed thereover that is configured to promote optimal light transmission. Each optical lens has a diameter that is between about 1.5 to 3 times the size of a respective LED die, and is shaped in the form of a hemisphere. Fillet segments are integral with and interposed between the adjacent optical lenses, and provide sufficient space between adjacent optical lenses so that the diameters of adjacent optical lenses do not intersect with one another.