Lens Flange Reflector Structure for LED Light Extraction

The patent converts the harmful light loss at the lateral surfaces of the flange portion into a beneficial effect by introducing a reflective member. This reflective member captures the light that would otherwise be lost and redirects it through the lens, transforming the harmful lateral surface loss into useful light extraction. The curved surface at the corner portions further optimizes this conversion by efficiently guiding the reflected light through the lens material.

The patent applies local quality by introducing a curved surface specifically at the corner portions of the flange, while maintaining standard flat surfaces elsewhere. This localized curvature is strategically placed where light loss occurs most severely, allowing the majority of the flange to remain simple for manufacturing while the critical corner regions are optimized for light management. The curved surface acts as a light-guiding feature that redirects photons away from total internal reflection and toward the lens.

The patent extends the adhesive application from a two-dimensional lateral surface coating to a three-dimensional configuration that includes the corner portions and interfaces between the flange, lens, and substrate. By positioning adhesive at the corner portions where the flange meets the lens and substrate, the patent creates additional light extraction pathways in previously underutilized spatial regions. This dimensional extension of adhesive placement captures and redirects corner light that would otherwise be lost, significantly improving overall light extraction efficiency.