Light-emitting Device Lens Misalignment Control
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Solution Overview
Problem
Conventional light-emitting devices face issues with misalignment during the joining of light-emitting elements and lenses, leading to imbalanced light emission strength distribution and reduced yields.
Innovation Solution
The solution involves a light-emitting device design where a light-emitting element with a rectangular emission surface is joined to a lens with a convex surface, where the distance between the centers of the convex surface and emission surface (Δ) is within a specific range (0 μm < Δ ≤ 450/r, with r being the ratio of the convex surface diameter to the emission surface length), ensuring controlled misalignment and improved joining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional joining methods are used for light-emitting element and lens, then joining is achieved, but misalignment occurs causing imbalanced light emission strength distribution
Solution Approach 1:
The patent applies preliminary action by pre-designing the lens with specific geometric parameters (convex surface curvature radius R, diameter D, and height h satisfying 0.3 ≤ h/R ≤ 0.8) before the joining process. This pre-configured geometry compensates for potential misalignment during joining, ensuring that even with some positional deviation, the light emission strength distribution remains balanced across the emission surface.
Solution Approach 2:
The patent utilizes parameter changes by optimizing the lens geometric parameters (curvature radius R, diameter D, height h) to specific ranges. By adjusting these parameters, the lens can accommodate misalignment while maintaining uniform light emission. The specific relationship 0.3 ≤ h/R ≤ 0.8 creates a tolerance buffer that transforms the sensitive alignment problem into a robust design.
2Ease of manufacture
If misalignment is not controlled, then joining process is simple, but light emission strength distribution becomes imbalanced
Solution Approach 1:
The patent applies asymmetry by designing the lens with a convex surface rather than a flat surface. The asymmetric convex geometry (with specific curvature and height ratios) creates a light extraction pattern that is inherently more tolerant to misalignment. The curved surface distributes light more evenly across the emission area compared to a flat surface, compensating for positional deviations without requiring complex alignment procedures.
3Illumination intensity
If alignment is strictly controlled, then light emission balance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent implements self-service by designing the lens geometry to automatically compensate for misalignment. The specific convex surface parameters (curvature radius R, diameter D, height h with 0.3 ≤ h/R ≤ 0.8) create a self-correcting optical system where the lens shape itself ensures balanced light emission even when misalignment occurs, eliminating the need for complex external alignment control mechanisms.
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 approach effectively controls the misalignment and enhances light extraction efficiency, improving the yield and performance of the light-emitting device by maintaining a balanced radiant intensity distribution.
Implementation Method 1
Using the convex lens can prevent a total reflection of light and improve light-extracting efficiency
Implementation Method 2
A bottom of the convex lens and a light-extracting surface are bonded by a refractive index relaxing material layer
Data Source
AI summary
A light-emitting device including:a light-emitting element; anda lens joined to the light-emitting element,wherein the light-emitting element has a rectangular light emission surface facing the lens,wherein the lens includes: an opposing surface facing the light-emitting element; and a convex surface oriented in an opposite direction to the opposing surface, andwherein as seen in a direction perpendicular to the light emission surface, a circumferential edge of the convex surface is circular, and, when a distance between a center of the convex surface and a center of the light emission surface is denoted by Δ (unit: μm); a length of a shortest edge of the light emission surface is denoted by L (unit: mm); a diameter of the circumferential edge of the convex surface is denoted by R (unit: mm); and R/L is denoted as r; formula (1):0<Δ≤450/r(1)is satisfied.