LED Chip Scale Packaging with Reflective Lens Curvature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light emitting diode (LED) packaging structures face challenges in achieving thin designs and precise optical alignment due to manufacturing complexities and optical shift inaccuracies, particularly with refractive lenses, which limit their application in display devices like liquid crystal display devices.
Innovation Solution
A light emitting diode chip scale packaging structure featuring a lens with an outer surface curve that complies with a polynomial equation, ensuring precise light direction and minimizing material usage, weight, and thickness, while allowing for a larger manufacturing tolerance and improved display effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a refractive lens is used to directly lead light from LED, then the manufacturing tolerance is larger, but it is very difficult to achieve a thin product due to physical threshold limitations
Solution Approach 1:
The patent employs a reflective lens with a specifically designed curved surface (paraboloid or ellipsoid geometry) to focus and direct light from the LED. This curved reflective surface achieves the desired light control with a thinner profile compared to conventional refractive lenses, resolving the contradiction between manufacturing tolerance and product thickness by using reflection rather than refraction.
Solution Approach 2:
The patent replaces the refractive optical system with a reflective optical system. Instead of using a refractive lens that relies on material thickness and refractive index to control light, the invention uses a reflective lens that directs light through reflection, thereby achieving thinner product design while maintaining larger manufacturing tolerance.
2Length of moving object
If a reflective lens is used to lead light toward bottom surface, then the design can be thinner, but the manufacturing process requires high accuracy with low optical shift tolerance
Solution Approach 1:
The reflective lens is designed with a specific curved surface geometry (paraboloid or ellipsoid) that provides inherent optical path optimization. This curved design enables the system to achieve thin profile while the specific geometric form factor provides robustness against manufacturing variations, effectively increasing optical shift tolerance compared to simpler reflective designs.
Solution Approach 2:
The patent optimizes the curvature parameters and geometric dimensions of the reflective lens to achieve a balance between thinness and manufacturing tolerance. By carefully selecting and adjusting the geometric parameters of the reflective surface, the design achieves both reduced thickness and increased tolerance to manufacturing variations.
3Manufacturing precision
If element disposing accuracy is improved during module assembly, then optical shift is reduced, but the cost and technical difficulty increase
Solution Approach 1:
The reflective lens with its specific curved geometry provides inherent optical path optimization that reduces sensitivity to element positioning variations. The curved surface design creates more robust optical performance that is less dependent on precise element disposal accuracy, thereby reducing the complexity of pack plate design and assembly requirements.
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 proposed structure enhances luminous efficiency and display effects by precisely directing light and reducing manufacturing costs and thickness, facilitating miniaturization and improved optical performance in LED-based devices.
Implementation Method 1
Another scheme of the direct type light emitting uses a refractive lens, which can directly lead a light from a light emitting diode as a light source to a plane to be imaged by the lens
Data Source
AI summary
A center point of the curve corresponding to the light emitting diode chip is a zero point of y-z coordinate axes. z is a variable of vertical axis of the curve. y is a variable of horizontal axis of the curve. ai is a constant coefficient in a term of ith degree. 3<n≤6.