LED Lens Ring Structure for Narrow Beam and Optical Axis Alignment
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Solution Overview
Problem
Existing semiconductor light emitting devices face challenges in achieving high forward emitted light intensity with narrow light distribution characteristics, and they often suffer from misalignment between the lens and the light emitting element due to molding deviations.
Innovation Solution
A semiconductor light emitting device is designed with a plane substrate, a semiconductor light emitting element mounted on the substrate, and a lens formed from resin that embeds the light emitting element. A circular ring-shaped metal ring body with regulation holes is used to define the lens bottom and create valley portions, ensuring accurate alignment and light condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a lens is formed by injecting resin, then the lens can seal the light emitting element, but it becomes difficult to achieve high forward emitted light intensity with narrow light distribution characteristics
Solution Approach 1:
The patent employs a lens with a spheroid surface instead of a simple spherical or flat surface. The spheroidal curvature is specifically designed to control light distribution, enabling narrow beam angles and high forward emitted light intensity. The curved surface refracts light rays to concentrate them in the forward direction, achieving the desired narrow light distribution while maintaining ease of manufacture through injection molding.
2Ease of manufacture
If a lens is formed by injecting resin, then the lens can be easily manufactured, but positional and optical axis deviations occur due to molding deviation
Solution Approach 1:
The invention implements a self-alignment mechanism where the lens structure automatically positions itself relative to the light emitting element during the injection molding process. The lens includes a bottom surface with a specific shape that cooperates with the light emitting element's mounting structure, enabling the lens to self-align and eliminate positional and optical axis deviations without requiring additional alignment steps or complex fixtures.
3Device complexity
If a simple lens structure is used, then manufacturing is easier, but the light distribution characteristics cannot be precisely controlled
Solution Approach 1:
The patent applies local quality by designing different regions of the lens with distinct functional characteristics. The lens includes a spheroidal top surface for light condensation, a specifically shaped bottom surface for alignment, and side surfaces with particular curvatures for light distribution control. Each region is optimized for its specific function, enabling precise light distribution control while maintaining overall structural simplicity suitable for injection molding.
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 achieves a semiconductor light emitting device with enhanced directivity characteristics, high intensity of forward emitted light, and accurate light distribution, while minimizing positional and optical axis deviations between the light emitting element and the lens.
Implementation Method 1
a lens which embeds the semiconductor light emitting element and condenses light emitted from the semiconductor light emitting element
Data Source
AI summary
A semiconductor light emitting device includes a plane substrate having a flat substrate surface, a semiconductor light emitting element mounted on the substrate surface, and a lens formed of a resin which embeds the semiconductor light emitting element and condenses light emitted from the semiconductor light emitting element. A circular ring-shaped metal ring body surrounding the semiconductor light emitting element, and a plurality of regulation holes arranged inside the metal ring body at positions rotationally symmetric with respect to the center of the metal ring body are provided on the substrate surface. A bottom of the lens is defined by the metal ring body and the regulation holes. A body part of the lens has a plurality of valley portions extending toward the top of the lens from the positions of the regulation holes. The top of the lens has a surface as a spheroid surface with an axis vertical to the substrate surface and passing through the center of the metal ring body as a major axis.