Self-Aligning Preformed Lens for LED Die Placement
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Solution Overview
Problem
Conventional light emitting device manufacturing processes require double-handling and precise alignment of light emitting elements, leading to increased costs and defective products due to misalignment with optics, even with self-supporting chips, as they still need to be placed on substrates for encapsulation.
Innovation Solution
A pre-formed lens with tapered walls facilitates easy insertion and accurate alignment of self-supporting light emitting chips, using adhesive for securement, and optional channels for air and adhesive escape, allowing for manual or automated precise placement without high-precision machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mounting processes are used to attach light emitting elements to substrates, then the light emitting elements can be secured and encapsulated, but misalignment with optics occurs leading to defective products
Solution Approach 1:
The light emitting element is designed with self-aligning features including tapered insertion walls that guide the element into proper alignment with the optics, and an enlarged bottom surface that provides a stable mounting base. The element self-aligns during insertion without requiring external alignment machinery, eliminating misalignment defects.
Solution Approach 2:
The light emitting element is pre-formed with integrated alignment features including tapered walls and an enlarged bottom surface before mounting. This preliminary preparation of alignment features eliminates the need for post-mounting alignment adjustments and ensures proper positioning with the optics from the start.
2Manufacturing precision
If high-precision machinery is used for placing light emitting elements, then alignment accuracy improves, but manufacturing cost increases
Solution Approach 1:
The light emitting element incorporates self-aligning features that enable accurate placement using simple, low-cost machinery. The tapered insertion walls guide the element into proper alignment automatically during insertion, eliminating the need for expensive high-precision placement equipment while maintaining alignment accuracy.
Solution Approach 2:
The tapered insertion walls act as an intermediary mechanism between the placement machinery and the light emitting element. These walls provide mechanical guidance that translates simple placement motions into precise alignment, serving as a mediator that eliminates the need for complex, expensive alignment systems.
3Ease of manufacture
If double-handling processes are used for mounting and encapsulating light emitting elements, then complete device assembly is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The mounting and encapsulation processes are merged into a single integrated operation. The light emitting element is mounted directly into the final device housing with integrated optics and encapsulation, eliminating the separate intermediate mounting step on temporary substrates. This reduces manufacturing process complexity while achieving complete device assembly.
Solution Approach 2:
The intermediate substrate used in conventional double-handling processes is extracted/removed from the manufacturing process. The light emitting element is mounted directly into the final device structure without requiring a temporary carrier substrate, eliminating an entire process step and reducing manufacturing complexity.
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 method enables accurate and efficient alignment of light emitting chips within lens structures, reducing manufacturing costs and defects by simplifying the insertion and alignment process, suitable for mass production.
Implementation Method 1
using adhesive for securement
Data Source
AI summary
A light emitting diode (LED) light source is disclosed. The LED light source comprises a lens structure that includes a hemispherical dome with a base. The LED light source comprises a cavity in the base. The cavity has an opening and a taper such that a cross-section area within the cavity is smaller than an area of the opening. The LED light source comprises a light emitting device comprising an LED die contacting the taper. The taper allows for easy insertion of the LED die into the lens structure. The taper serves to accurately align the LED die when the LED die is inserted.