Light Emitting Device Lens Fixation via Segmented Resin Bonding
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Solution Overview
Problem
In light emitting devices with a lens and light emitting element, accurate fixation of the lens is crucial for performance, but excessive resin can cause the lens to float or lean off position, while insufficient resin leads to poor bonding and non-uniform light transmittance.
Innovation Solution
The device incorporates a support with male and female portions between the lens and light emitting element, where the number of female portions exceeds male portions, allowing excess resin and bubbles to be discharged, ensuring proper positioning and bonding without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If light transmitting resin is loaded between the lens and light emitting element for fixation, then the lens can be bonded to the support, but excessive resin causes the lens to float or lean off position
Solution Approach 1:
The invention divides the bonding interface into multiple discrete contact points using male and female portions (protrusions and recesses) instead of a continuous resin layer. This segmentation allows the lens to be firmly bonded at specific locations while preventing excessive resin from causing floating or leaning, as the resin is confined to specific regions between the male and female portions.
Solution Approach 2:
The invention creates different local conditions at the bonding interface by providing multiple male portions on one component and corresponding female portions on the other. This local differentiation ensures that resin is present only where needed for bonding, while maintaining precise positioning at other locations, thus resolving the contradiction between bonding strength and positioning accuracy.
2Manufacturing precision
If the amount of resin loaded in the recess is too small, then the lens positioning is maintained, but the bonding strength for the lens is insufficient
Solution Approach 1:
By segmenting the bonding interface into multiple discrete male and female portions, the invention ensures that sufficient resin is present at each bonding location without requiring excessive overall resin volume. This segmentation allows precise control of resin distribution, maintaining positioning accuracy while ensuring adequate bonding strength at each contact point.
Solution Approach 2:
The invention applies the principle of partial action by providing more female portions than male portions (n+α vs n). This ensures that all male portions can be fully engaged with corresponding female portions, guaranteeing sufficient bonding strength without requiring excessive resin, as the additional female portions accommodate the resin volume while maintaining proper positioning.
3Manufacturing precision
If bubbles are trapped between the lens and bonding resin, then the lens positioning may be maintained, but uniform light transmittance cannot be obtained
Solution Approach 1:
The segmented male and female portion structure creates multiple small bonding zones rather than one large interface, which reduces the likelihood of bubble entrapment. The resin is confined to specific regions between the protrusions and recesses, making it easier to eliminate bubbles and ensuring uniform light transmittance while maintaining positioning accuracy.
Solution Approach 2:
The invention extracts harmful bubbles from the bonding interface by providing escape paths through the multiple female portions. The excess resin and trapped bubbles can be discharged through the additional female portions during the bonding process, ensuring that the final bonding interface is free from bubbles and provides uniform light transmittance.
4Device complexity
If the lens is fixed by bonding resin alone, then the structure is simple, but the lens cannot be accurately fixed at the predetermined position
Solution Approach 1:
The invention introduces male and female portions (protrusions and recesses) as simple geometric features into the bonding structure. These segmented contact points provide precise mechanical positioning guidance while maintaining overall structural simplicity. The lens is accurately positioned through the engagement of these portions without requiring complex fixation mechanisms.
Solution Approach 2:
The male and female portions act as intermediary mechanical features between the lens and support, providing positioning guidance while the resin provides bonding. This intermediary structure enables accurate lens fixation at predetermined positions without significantly increasing overall device complexity, as the male and female portions are simple geometric modifications to existing components.
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 configuration ensures reliable and easy lens positioning, preventing optical axis deviation and enhancing adhesion, resulting in improved light emitting performance and uniform transmittance.
Implementation Method 1
Light transmitting resin is filled in the light transmitting region between the lens and the light emitting element, so that the lens is fixed to the support
Data Source
AI summary
A light emitting device includes light transmitting resin loaded between a lens and a light emitting element. The structure of the device enables the lens to be fixed to a required position without reducing the light transmittance.The light emitting device 1 includes a light emitting element 2 and a separate lens 3 supported by a support member 4. The lens 3 is fixed to the support member 4 by hardening the resin 13 between the element 2 and the lens 3 in the support member 4. Mutually engaging male and female portions are provided between the support member 4 and the lens 3. N male portions (n is a positive integer) are provided for (n+α) female portions (α is a positive integer). The female portions allow the resin 13 to communicate with the outside of the device. The α female portions serve as a leak portion for discharging the resin 13 or bubbles to the outside when the lens 3 is fixed.