LED Lens Segmentation for Uniform Illumination
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Solution Overview
Problem
Existing methods for producing LED-based illuminating devices for liquid crystal displays are costly and lack accuracy due to the use of complex lens shapes and multiple molds, leading to high production costs and non-uniform light distribution.
Innovation Solution
The use of LED packages with a lens design that includes symmetrically arranged LEDs of different colors, allowing for isotropic light distribution and reduced material usage, along with a single mold production process to minimize costs and enhance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a lens with a funnel portion is used to reflect light vertically, then light distribution is improved, but production complexity increases due to requiring multiple molds
Solution Approach 1:
The lens is divided into two functional portions: a funnel-shaped portion for light collection and a protruded ring portion for total internal reflection. This segmentation allows each portion to be optimized independently while simplifying the overall manufacturing process by enabling single-mold production.
Solution Approach 2:
The protruded ring portion acts as an intermediary structure that enables total internal reflection without requiring complex multi-mold assembly. This intermediate structure simplifies the production process while achieving the desired light reflection effect.
2Reliability
If a lens with a protruded ring portion is used for total internal reflection, then light reflection efficiency is improved, but manufacturing accuracy decreases due to mold entanglement
Solution Approach 1:
The lens structure is segmented into the funnel-shaped portion and the protruded ring portion, where the ring portion is integrated into the funnel portion. This integration eliminates the need for separate molding and assembly operations, thereby maintaining high manufacturing precision while achieving effective total internal reflection.
3Manufacturing precision
If multiple molds are used to produce the lens, then production accuracy is improved, but production cost increases
Solution Approach 1:
The funnel-shaped portion and the protruded ring portion are merged into a single integrated lens structure that can be produced using one mold. This merging eliminates the need for multiple molds and assembly operations, significantly reducing production costs while maintaining manufacturing precision through optimized single-mold design.
4Area of stationary object
If LED packages are congregated in a large area, then illumination coverage is improved, but light uniformity decreases without proper arrangement
Solution Approach 1:
LEDs within each package are arranged in specific asymmetric patterns (such as triangular or linear arrangements) that, when combined with the symmetric distribution of multiple packages across the display area, achieve both wide coverage and uniform light distribution. The asymmetric LED arrangement within packages complements the symmetric package layout.
Solution Approach 2:
Each LED package is designed with specific local characteristics (such as the protruded ring portion for total internal reflection and the funnel-shaped portion for light collection) that optimize light emission in particular directions. This local optimization ensures uniform overall illumination when packages are distributed across the large display area.
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 results in a cost-effective and uniformly illuminated liquid crystal display with improved light distribution, reducing production complexity and increasing efficiency.
Implementation Method 1
a saw-toothed lens portion for refracting light emitted from the light source in such a manner that most of the light going out of the saw-toothed lens portion is made to be substantially vertical to the center axis of the lens proper
Implementation Method 2
a funnel-shaped lens portion connected to the saw-toothed lens portion to reflect the light emitted from the light source in such a manner that most of the light going out of the funnel-shaped lens portion is made to be substantially vertical to the center axis of the lens proper
Implementation Method 3
The funnel portion 100 is designed as a total internal reflection (TIR) surface. The TIR surface reflects rays of light so that they may go out of the lens 1 at an angle of as approximately 90° as possible making to the z-axis
Data Source
AI summary
A liquid crystal display device includes a liquid crystal panel and an illuminating device having a plurality of LED packages which include LED's and a lens. Each LED package includes a high refractive index member containing a substance having a larger refractive index than that of a material forming the lens and which seals the LED. The lens is shaped to have a recess near its center, and is shaped so that a moving radius increases as a polar angle increases within a range of 0 to 80 degrees. The moving radius is defined as a distance starting from the lens center and ending in the lens surface, and the polar angle is defined as an angle that is made by the moving radius to the center axis that is vertical to a plane on which said LED package is located and passing through the center of the lens.