LED Array Lens Structure for Dense Packing and Light Transmission
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Solution Overview
Problem
Conventional light-emitting assemblies with LED arrays are limited in achieving optimized packaging and lens construction for high-light output and transmission in a small spatial package, which restricts their end-use applications and is 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 over LED dies, then the LED dies are protected from physical damage and light emission is facilitated, but the spatial package size increases and packaging density is reduced
Solution Approach 1:
The patent divides the lens structure 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 optimized for its specific LED die while reducing overall spatial requirements and improving packaging density.
Solution Approach 2:
The patent applies different lens configurations and materials to different locations on the substrate. Each lens is specifically designed for its corresponding LED die, allowing localized optimization of protection and light emission while minimizing overall package size.
2Illumination intensity
If conventional lens constructions are used, then light emission is facilitated, but the light output/transmission efficiency is limited and packaging is not optimized
Solution Approach 1:
The patent changes the parameters of the lens system by using individual lenses with optimized diameters, shapes, and materials for each LED die. This allows customization of light transmission parameters to maximize efficiency while maintaining compact packaging.
Solution Approach 2:
The patent employs composite lens structures that may include multiple materials with different optical properties, allowing optimization of both light transmission efficiency and physical protection while maintaining compact dimensions.
3Area of stationary object
If LED dies are arranged with optimized packing density, then space utilization is improved, but the lens construction complexity increases
Solution Approach 1:
By segmenting the lens system into individual lenses for each LED die, the patent enables optimized packing density while managing complexity through modular construction. Each lens unit can be independently designed and positioned to achieve optimal spatial arrangement.
4Shape
If conventional molding techniques are used for lens formation, then lenses can be shaped into desired configurations, but the manufacturing cost and labor requirements increase
Solution Approach 1:
The segmented lens approach allows for simpler, more cost-effective manufacturing compared to forming a single complex pre-formed dome. Individual lenses can be manufactured using standard techniques and then positioned on each LED die, reducing overall manufacturing complexity and cost.
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
Each optical lens, or lens per die (LPD), is shaped and sized to promote optimal light transmission of a respective LED die. The lens is formed from silicone that comprises phosphor particles dispersed therein.
Implementation Method 2
Light emitting assemblies as disclosed herein comprise an LED array made up of a number of LED dies arranged in a fixed position relative to one another on a common substrate. The LED dies are arranged relative to one another having an optimized packing density that is not too tight and that is not too loose.
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.