Optical Element with Adjust Portion for Light Emitting Unit Packaging
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Solution Overview
Problem
Conventional optical elements face challenges in packaging with light emitting units and other structural components due to inadequate consideration of manufacturing processes.
Innovation Solution
An optical element with a concavo-convex shape at a boundary surface between two medium layers of different refractive indices, along with an adjust portion to maintain a certain distance from the concavo-convex shape, facilitating easier packaging with light emitting units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a regular-interval microlens array structure is used, then the optical function is achieved, but variability occurs in light intensity due to diffraction effects
Solution Approach 1:
The patent applies asymmetry by using a random arrangement of microlenses instead of a regular-interval structure. This random placement eliminates the periodic diffraction patterns that cause light intensity variability, thereby improving reliability while reducing diffraction-related harmful effects.
2Reliability
If random placement of microlenses is used, then light intensity uniformity is improved, but the intensity of emitted light decreases
Solution Approach 1:
The patent changes the structural parameters of the microlens array by introducing a support structure that holds microlenses at specific distances from the substrate. This parameter change allows the microlenses to be positioned optimally for both uniform light distribution and maintaining high emitted light intensity, resolving the contradiction between uniformity and intensity.
3Reliability
If conventional optical element design is used, then optical function is achieved, but packaging with light emitting units and structural components is difficult
Solution Approach 1:
The patent merges the optical element with the substrate by integrally forming the support structure as part of the substrate. This integration simplifies the packaging process by reducing the number of separate components that need to be assembled, thereby improving ease of manufacture while maintaining optical functionality.
Solution Approach 2:
The support structure is preliminarily formed on the substrate before the light emitting units are mounted. This preliminary action creates predetermined positioning features that facilitate subsequent packaging and assembly operations, making the manufacturing process easier and more efficient.
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 optical element's design enhances packaging efficiency by allowing precise alignment and integration with light emitting units, improving the overall manufacturing process of optical system devices.
Implementation Method 1
a first medium layer with a first refractive index; a second medium layer with a second refractive index that is higher than the first refractive index; and a concavo-convex shape at a boundary surface therebetween
Data Source
Figure 1(a)~1(d)
Figure 2(a)~2(d)
Figure 3(a)~3(c)
AI summary
An optical element that can be easily packaged with other structural components, an optical system device that utilizes such an optical element, and a method for manufacturing such an optical system device are provided. An optical element includes a concavo-convex shape 20 which accomplishes an optical function and which is provided at a boundary surface 11 between a first medium layer 1 with a first refractive index and a second medium layer 2 with a second refractive index that is higher than the first refractive index. An adjust portion 7 to maintain a certain distance from the concavo-convex shape 20 is formed at a first-medium-layer-1 side relative to the concavo-convex shape 20.