LED Package Convex Lens Uniform Light Distribution

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Solution Overview

Problem

Conventional LED packages with complex lens shapes and refractive designs suffer from bright spots, high manufacturing costs, and low light efficiency, particularly in miniaturized LCD applications, where they fail to uniformly emit light and achieve a large beam angle.

Innovation Solution

An LED package with a housing and a convex-lensed LED assembly that features a seating recess with a circular or polygonal horizontal section, utilizing a lens with a Full Width at Half Maximum (FWHM) beam angle of at least 120 degrees, made from materials like glass, silicone, or resin, allowing for simpler manufacturing and improved light distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a complex lens shape with refractive design is used, then light can be laterally emitted, but bright spots appear and uniformity is poor

Engineering Contradiction:

Improvelight emission uniformityVSAvoidlens shape complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent inverts the conventional lens design approach by using a convex lens shape instead of a complex refractive design. The convex lens with a large curvature radius (R≥0.5mm) redirects light in a different manner, achieving uniform light distribution without the bright spot issues caused by traditional refractive lens designs.

Inventive Principle:

Principle #13The other way round (Inversion)

2Illumination intensity

If a complex lens shape is used, then light can be laterally emitted, but manufacturing process becomes difficult and costs increase

Engineering Contradiction:

Improvelateral light emissionVSAvoidlens manufacturing ease

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent simplifies manufacturing by inverting from complex refractive lens designs to a simple convex lens shape with large curvature radius. This convex design is easier to manufacture using conventional processes while still achieving the desired lateral light emission through its geometric shape rather than complex refraction patterns.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the key geometric parameter of the lens from complex multi-surface refraction designs to a simple convex shape defined by a large curvature radius (R≥0.5mm). This parameter change simplifies the manufacturing process while maintaining the light redirection function through geometric optics rather than complex refraction.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional LED size (at least 1 mm2) is used, then lens can be adequately sized, but light efficiency decreases

Engineering Contradiction:

Improvelens and LED assemblyVSAvoidlight efficiency

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent changes the size parameter of the LED to less than 1 mm2, enabling miniaturization of the overall package. The convex lens with large curvature radius is designed to work effectively with these smaller LEDs, maintaining adequate light collection and redirection efficiency despite the reduced LED size, thus improving overall light efficiency while enabling compact designs.

Inventive Principle:

Principle #35Parameter changes

4Productivity

If conventional LED package is used, then light can be emitted, but beam angle is insufficient for miniaturization

Engineering Contradiction:

Improveminiaturization capabilityVSAvoidbeam angle

Core Design Contradiction:

ProductivityVSIllumination intensity

Solution Approach 1:

The patent employs a convex lens with a large curvature radius (R≥0.5mm) to achieve a wide beam angle of 120 degrees or more. The spherical/convex geometry of the lens effectively redirects light over a wide angular range, enabling miniaturization of the display device while maintaining adequate illumination coverage.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 without bright spots, increases the beam angle, minimizes color mixing regions, and simplifies the manufacturing process, leading to miniaturization and improved light efficiency in LCD backlight units.

Implementation Method 1

a lens with a convex surface forming a predetermined sag, covering an upper part of the light emitting diode, the lens having a beam angle with a Full Width at Half Maximum (FWHM) in the range of at least 120 degrees

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS8197090B2LED package and backlight unit using the same

Publication Date: 2012.06.12 SAMSUNG ELECTRONICS CO LTD

AI summary

The invention relates to an LED package having a large beam angle of light emitted from an LED, simplifying a shape of a lens and an assembly process, and to a backlight unit using the same. The LED package includes a housing with a seating recess formed therein and at least one LED seated in the seating recess. The LED package also includes a lens having a predetermined sag on an upper side thereof, covering an upper part of the LED. The LED package and the backlight unit using the same can emit light uniformly without bright spots formed in an output screen, uses a simpler shaped lens with an increased beam angle, and minimizes a color mixing region to achieve miniaturization.