LED Package Recessed Lens Structure for Light Extraction
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Solution Overview
Problem
Conventional LED packages suffer from reduced light extraction efficiency due to light being emitted through peripheral portions instead of the lens portion during the formation of the lens molding layer, which affects the overall light emission efficiency.
Innovation Solution
The LED package design includes a body molding layer with recess regions around the opening, where the peripheral portion of the lens molding layer fills these recesses, reducing light emission through the peripheral portion and enhancing light extraction efficiency by ensuring that most light is emitted through the dome-shaped lens portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a lens molding layer is formed in conventional LED packages, then the structure is simplified and manufacturing is easier, but light extraction efficiency deteriorates because light is emitted through peripheral portions instead of the lens portion
Solution Approach 1:
The lens molding layer is segmented into a central lens portion and a peripheral portion, with the peripheral portion positioned in recess regions. This segmentation allows light to be directed primarily through the central lens portion while the peripheral portion is positioned where it does not interfere with light extraction, thus resolving the contradiction between manufacturing simplicity and light extraction efficiency.
Solution Approach 2:
The body molding layer is designed with recess regions at the periphery, creating local structural variations. The peripheral portion of the lens molding layer is positioned specifically within these recess regions, allowing different areas to serve different functions: the central area for light emission and the peripheral recess areas for structural support without light interference.
2Loss of energy
If the peripheral portion of the lens molding layer is reduced or eliminated, then light extraction efficiency improves, but manufacturing complexity increases and the structure becomes more difficult to produce
Solution Approach 1:
The body molding layer is pre-formed with recess regions before the lens molding layer is applied. This preliminary action creates the necessary structural features that guide the peripheral portion of the lens molding layer into the correct position, simplifying the overall manufacturing process while maintaining high light extraction efficiency.
Solution Approach 2:
The peripheral portion of the lens molding layer is merged with the recess regions of the body molding layer, creating an integrated structure. This combination allows the peripheral portion to provide structural support while being positioned in a way that does not interfere with light extraction through the central lens portion.
3Ease of manufacture
If the lens molding layer covers the entire opening including peripheral regions, then manufacturing is simpler and coverage is more complete, but light emission through the peripheral portion reduces overall light extraction efficiency
Solution Approach 1:
The lens molding layer is designed with different functional zones: a central lens portion for light emission and a peripheral portion positioned in recess regions. This local differentiation ensures that the peripheral areas do not block light extraction while still providing structural coverage and support.
Solution Approach 2:
The lens molding layer is segmented into functional zones with the peripheral portion positioned in recess regions. This segmentation allows the peripheral portion to provide structural coverage without interfering with light emission, resolving the contradiction between complete coverage and light extraction efficiency.
Data Source
AI summary
A light emitting diode (LED) package includes a body including a body molding layer having an opening, and a metal plate surrounded by the body molding layer, an upper surface of the metal plate being exposed through the opening of the body molding layer; an LED chip on the upper surface of the metal plate exposed through the opening of the body molding layer; and a lens molding layer, the lens molding layer including a lens portion on the LED chip and a peripheral portion on the body molding layer, wherein the body molding layer includes a plurality of recess regions adjacent to the opening of the body molding layer and extending outwardly in a radial direction of the opening of the body molding layer, and the peripheral portion fills the plurality of recess regions.