Integral Distorted Lenses for LED Chip Batch Processing
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Solution Overview
Problem
Conventional light emitter devices with individually encapsulated or molded LED chips are expensive and time-consuming to produce, limiting the adoption of brighter and more efficient LED products.
Innovation Solution
Batch processing of chip on board (COB) light emitter devices with integrally formed, distorted lenses that are sized and shaped to enhance brightness and efficiency, allowing for simultaneous die attachment, wirebonding, and molding of LED chips, reducing processing costs and time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individually molded lenses are used for LED chips, then manufacturing precision and protection are improved, but processing time and cost increase
Solution Approach 1:
Multiple individual LED chip lenses are merged into a single integral lens structure that covers multiple LED chips simultaneously. This is achieved by providing an integral lens over a plurality of LED chips, where the integral lens is formed as a single piece rather than molding separate lenses for each chip. The merging reduces the number of molding operations from multiple individual lens moldings to a single integral lens molding, thereby improving productivity while maintaining manufacturing precision through the unified structure.
Solution Approach 2:
The integral lens serves multiple functions simultaneously: it acts as the optical lens for multiple LED chips, provides protection for the LED chips, and enables batch processing. By designing a universal lens structure that can cover and protect multiple LED chips at once, the system achieves multi-functionality that reduces processing steps and time while maintaining the necessary manufacturing precision for each individual chip's optical output.
2Reliability
If individually encapsulated LED chips are used, then protection and optical performance are improved, but processing time and cost increase
Solution Approach 1:
Multiple individual encapsulation processes are merged into a single batch encapsulation operation. The integral lens structure allows multiple LED chips to be encapsulated simultaneously in one molding cycle rather than requiring separate encapsulation steps for each chip. This merging maintains the protective function for each chip while dramatically reducing the total processing time and associated costs.
Solution Approach 2:
The integral lens is designed to preliminarily cover and protect multiple LED chips before final assembly completion. By having the integral lens structure in place that can accommodate multiple chips simultaneously, the protection function is established in advance for all chips together, enabling subsequent batch processing operations and reducing overall manufacturing time.
3Productivity
If batch processing is implemented, then productivity and cost efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The batch processing system is segmented into modular components: multiple LED chips are arranged in a systematic pattern on a substrate, and the integral lens is designed with corresponding segmented regions that align with individual chips. This segmentation allows the complex batch processing operation to be broken down into manageable steps while maintaining overall efficiency. The modular design of the integral lens with distinct regions for each chip simplifies the manufacturing process despite the batch processing complexity.
Solution Approach 2:
The integral lens is designed with asymmetric features that accommodate the specific arrangement and optical requirements of multiple LED chips. Rather than using a simple symmetric design, the lens incorporates asymmetric curvature and thickness variations tailored to the batch configuration. This asymmetric design optimizes light extraction and optical performance for each individual chip within the batch while enabling the overall batch processing efficiency.
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 results in improved brightness, light extraction, and manufacturability of LED products at lower costs, suitable for various lighting applications, including personal, industrial, and commercial use.
Implementation Method 1
lenses that are sized and shaped to enhance brightness and efficiency
Data Source
AI summary
Light emitter devices and methods are provided herein. In some aspects, emitter devices and methods provided herein are for light emitting diode (LED) chips, and can include providing a substrate and a plurality of LED chips over the substrate. The devices and methods described herein can further include providing a plurality of integral lenses over the LED chips, where at least some of the lenses can be distorted. In some aspects, the distorted lenses can be compressed towards each other along one or more directions.