Lens Assembly Structure for Light Leakage Shielding

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Solution Overview

Problem

Existing light emitting devices face challenges in effectively reducing light leakage and enhancing structural stability of lenses used in mobile devices, particularly in cellular phones, where metal films used for light reflection are prone to degradation and do not provide adequate structural support.

Innovation Solution

A lens design incorporating a cover part formed of thermosetting first resin with a flange part having a greater thickness than the connection part, and a light-shielding part made of thermosetting second resin with higher light absorptance or reflectance, which is applied to cover the lateral surfaces of the connection part and flange part, ensuring stable bonding and reduced light leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal film is used as the light-reflecting member formed by vacuum vapor deposition, then light reflection is achieved, but the structural stability and support are insufficient and the metal film is prone to degradation

Engineering Contradiction:

Improvelight reflection performanceVSAvoidstructural stability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite structure consisting of a translucent resin cover part and a light-shielding part made of black resin. This composite material approach replaces the metal film with a combination of materials that provide both light reflection (through the translucent cover part) and structural stability (through the integrated light-shielding part made of durable black resin), eliminating the degradation issues associated with metal films while maintaining optical functionality.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If the flange part has the same thickness as the connection part, then manufacturing is simpler, but bonding stability is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidbonding stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by making the flange part thicker than the connection part. This localized increase in thickness at the flange provides enhanced bonding stability and structural support where it is most needed for mounting and connection, while keeping the rest of the structure (connection part) thinner and easier to manufacture. This differentiated thickness design optimizes both manufacturing ease and bonding reliability.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If the lateral surfaces of the connection part and flange part are left uncovered, then manufacturing is simpler, but light leakage occurs

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidlight leakage

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent merges the light-shielding function with the structural cover part by integrating the light-shielding part made of black resin directly onto the lateral surfaces of the connection part and flange part. This integrated design eliminates light leakage from lateral surfaces without requiring separate additional components or complex manufacturing processes, as the light-shielding part is formed as an integral component of the lens assembly.

Inventive Principle:

Principle #5Merging (Combining)

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

The design provides enhanced structural stability and significantly reduces light leakage by absorbing or reflecting light at the lateral sides of the lens, maintaining the integrity and functionality of the light emitting device.

Implementation Method 1

a light-shielding part made of thermosetting second resin with higher light absorptance or reflectance, which is applied to cover the lateral surfaces of the connection part and flange part, ensuring stable bonding and reduced light leakage

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 2

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20250389923A1Lens and light emitting device

Publication Date: 2025.12.25 NICHIA CORP

AI summary

A lens including a cover part and a light-shielding part. The cover part has a lens part, a connection part extending outward from the lens part, and flange part(s) extending downward from the connection part. The lens part and the flange part(s) define a recess having an opening facing downward. The lens part defines a bottom surface of the recess. The flange part(s) extend from the bottom surface and define lateral surfaces, which define the opening of the recess. The lens part has a convex lens and a light incidence surface with projections. The projections are arranged in concentric circles or ellipsoids in plan view. The flange part(s) each extends downward beyond the projections. The lens part, the flange part(s), and the connection part are continuous to one another, and the light-shielding part covers at least a portion of an outer lateral surface of the flange part(s).