Lens Flange Reflector Structure for Light Extraction Efficiency

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Solution Overview

Problem

Existing light-emitting devices face challenges in improving light extraction efficiency, particularly due to light loss at the lateral surfaces of the lens flange portion.

Innovation Solution

A light-emitting device configuration that includes a base member, a light-emitting element, a lens with a flange portion, and a reflective member disposed on the lateral surfaces of the flange to reflect light back into the lens, utilizing a curved shape at corner portions to minimize light loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is provided on the lateral surfaces of the lens to secure the lens, then the lens is firmly attached to the base member, but light extraction efficiency deteriorates due to light loss at the lateral surfaces

Engineering Contradiction:

Improvelens attachment strengthVSAvoidlight extraction efficiency

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The patent converts the harmful light loss at the lateral surfaces into a beneficial effect by introducing a reflective member. This reflective member captures the light that would otherwise be lost and redirects it into the lens, transforming the harmful light loss into useful light extraction enhancement.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The reflective member acts as an intermediary between the base member and the lens. It is disposed between the lateral surfaces of the lens flange portion and the base member, serving as a mediating element that reflects light while allowing the adhesive to secure the lens firmly to the base member.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the lens flange portion has a sharp corner shape, then manufacturing is simplified, but light loss increases at the corner portions

Engineering Contradiction:

Improvelens manufacturing simplicityVSAvoidlight loss at corner portions

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent applies curvature to the corner portions of the lens flange portion by providing a curved surface at each corner. This curved surface design reduces light loss at the corners compared to sharp corners, while still maintaining ease of manufacture through a relatively simple geometric modification.

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

Enhances light extraction efficiency by reflecting light that would otherwise be lost, thereby improving the overall light output of the device.

Implementation Method 1

a reflective member disposed in contact with the upper surface of the base member and a lateral surface of the flange portion

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS12504149B2Light-emitting device

Publication Date: 2025.12.23 NICHIA CORP

AI summary

A light-emitting device includes: a base member having an outer lateral surface, an upper surface meeting the outer lateral surface, and a recess on an upper surface side; a light-emitting element disposed in the recess; a lens disposed on the upper surface of the base member and including a lens portion and a flange portion; and a reflective member disposed in contact with the upper surface of the base member and a lateral surface of the flange portion.