LED Package Diffuser Lens for Uniform Wide-Angle Light Emission
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Solution Overview
Problem
Conventional LED packages struggle with uniform light emission and limited radiating angles, leading to increased component counts and manufacturing costs in LCD backlight units, as they primarily emit light forward without achieving wide-angle diffusion or excellent color reproducibility.
Innovation Solution
An LED package design incorporating a diffuser within the encapsulant and a lens part made of materials mixed with phosphor and diffuser, utilizing an opal-based diffuser material like barium titanate or titanium dioxide to achieve uniform light emission in a wide radiating angle, reducing the thickness and complexity of the lens while allowing for varied configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional LED packages use phosphor and diffuser in wavelength-converting material part, then color mixing is achieved, but light emission is not uniform and radiating angle is limited
Solution Approach 1:
The patent extracts the diffuser function from the wavelength-converting material part and places it in a separate lens part. The lens part contains a diffuser layer that is positioned above the LED chip, allowing light to be diffused after emission. This separation enables independent optimization of color mixing (in wavelength-converting material) and light diffusion (in lens part), achieving both uniform emission and wide radiating angle without the constraints of combining both functions in one component.
2Illumination intensity
If conventional LED packages use hollow lamp housing structure, then light diffusion is achieved, but package thickness cannot be reduced
Solution Approach 1:
The patent transitions from a hollow lamp housing structure (three-dimensional volume occupation) to a planar lens part structure (two-dimensional surface integration). The lens part is positioned directly above the LED chip in a flat configuration, integrating the diffuser layer within this planar structure. This dimensional change allows light diffusion functionality to be achieved without increasing package thickness, as the diffuser operates in the lateral plane rather than requiring vertical hollow space.
3Reliability
If conventional LED packages use multiple components for color mixing, then color reproducibility is improved, but device complexity increases
Solution Approach 1:
The patent merges the diffuser functionality with the lens part, creating an integrated component that performs both light gathering and light diffusion. The lens part contains a diffuser layer that is positioned above the LED chip, allowing light to be diffused after emission. This integration reduces the total component count while maintaining color mixing performance, as the diffuser is now part of the lens assembly rather than a separate element.
4Ease of manufacture
If conventional LED packages emit light forward only, then manufacturing is simplified, but light utilization efficiency decreases
Solution Approach 1:
The patent introduces a reflective frame surrounding the LED chip that dynamically redirects light. The reflective frame has a specific shape and positioning that reflects light emitted in various directions back toward the lens part and forward emission direction. This dynamic light management system adapts to light emission patterns, converting backward or lateral light into useful forward emission, thereby improving overall light utilization efficiency while maintaining manufacturing simplicity through the use of a standard reflective frame structure.
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 uniform light emission across a wide angle without distortion, reducing the number of LED packages needed and lowering manufacturing costs by achieving efficient color mixing and improved color reproducibility, suitable for LCD backlight units.
Implementation Method 1
a diffuser is applied to an encapsulant disposed in an upper part of an LED chip to achieve color mixing, enabling uniform emission without distortion of light from the LED chip in a wide radiating angle
Implementation Method 2
the lens part is made of a material mixed with a phosphor
Data Source
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AI summary
The invention relates to an LED package for facilitating color mixing using a diffuser and a manufacturing method of the same. The LED package includes a substrate with an electrode formed thereon, and an LED chip mounted on the substrate. The LED package also includes an encapsulant applied around the light emitting diode chip, containing a diffuser. The LED package further includes a lens part disposed on the light emitting diode chip and the encapsulant to radiate light in a wide angle. The LED package allows light from the light emitting diode chip to be emitted out of the package without distortion. The invention allows light to exit through the encapsulant containing the diffuser and the lens part, achieving uniform diffusion and emission of light from the LED chip, thereby increasing a radiating angle and obtaining a uniform light source.