Optical Lens with Curved Bottom Surface for Light Emitting Module

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Solution Overview

Problem

Conventional light emitting modules face challenges in optimizing luminance distribution and reducing optical loss due to the limitations of existing optical lens designs, particularly in controlling the output angle of light and preventing interference between adjacent lenses.

Innovation Solution

The optical lens features a unique design with a recessed bottom surface that is upwardly convex, a light input surface with a curved shape, and multiple light output surfaces, including a curved first surface and a flat second surface, which allows for the control of luminance distribution by adjusting the emission angle and incorporating an absorption layer on the circuit board to manage unnecessary light, thereby reducing optical loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a conventional optical lens design is used, then the structure is simple, but the luminance distribution cannot be controlled and optical loss increases

Engineering Contradiction:

Improveluminance distributionVSAvoidoptical lens structure

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The optical lens is divided into multiple functional surfaces: a light input surface, a first light output surface, and a second light output surface. Each surface is optimized independently to control light propagation in specific directions, enabling precise luminance distribution control while managing structural complexity through functional segmentation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the optical lens are designed with different optical properties. The first light output surface has a specific curvature radius optimized for central light emission, while the second light output surface is positioned and shaped to control peripheral light emission. This local optimization allows precise control of luminance distribution across different spatial zones.

Inventive Principle:

Principle #3Local quality

2Illumination intensity

If the bottom surface of the optical lens is flat, then the manufacturing is easier, but optical loss occurs and light uniformity deteriorates

Engineering Contradiction:

Improvelight uniformityVSAvoidbottom surface fabrication

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The bottom surface of the optical lens is designed with a specific curvature rather than being flat. This curved bottom surface optimizes light propagation paths, improves light uniformity by distributing light more evenly across the output surfaces, and reduces optical loss through better optical coupling with the light emitting device. The curvature is specifically optimized to match the light emitting device's emission characteristics.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Area of stationary object

If the output angle of light is increased, then the light coverage area expands, but the luminance distribution control deteriorates

Engineering Contradiction:

Improvelight coverage areaVSAvoidluminance distribution control

Core Design Contradiction:

Area of stationary objectVSIllumination intensity

Solution Approach 1:

The optical lens separates light output into two distinct surfaces: the first light output surface optimized for central light emission at specific angles, and the second light output surface optimized for peripheral light emission. This segmentation allows different regions to emit light at optimized angles, expanding overall coverage while maintaining precise luminance distribution control in each zone.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The optical lens design optimizes specific geometric parameters including the curvature radius of the first light output surface, the position and shape of the second light output surface, and the overall lens dimensions. These parameters are carefully tuned to control light emission angles and luminance distribution, achieving both wide coverage and precise control through parameter optimization.

Inventive Principle:

Principle #35Parameter changes

4Loss of energy

If no absorption layer is used, then the device complexity is reduced, but optical loss increases due to reflected light

Engineering Contradiction:

Improveoptical lossVSAvoidabsorption layer structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

Instead of allowing reflected light from the circuit board to be wasted or cause interference, an absorption layer is introduced to deliberately absorb these reflected rays. This converts the potentially harmful reflected light into beneficial energy dissipation, reducing optical loss and improving overall system efficiency. The absorption layer is strategically positioned to capture specific reflected light paths.

Inventive Principle:

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

5Productivity

If adjacent optical lenses are placed close together, then the productivity increases, but light interference between lenses occurs

Engineering Contradiction:

Improvelens arrangement densityVSAvoidlight interference

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The optical lens design optimizes the emission characteristics of different regions to reduce interference with adjacent lenses. The first and second light output surfaces are positioned and shaped to direct light primarily in intended directions, minimizing stray light that could interfere with neighboring lenses. This local optimization of light emission patterns allows denser lens arrangements while preventing harmful interference.

Inventive Principle:

Principle #3Local quality

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 design enhances luminance distribution by controlling the output angle of light, minimizing optical loss, and preventing interference between adjacent lenses, resulting in improved light uniformity and efficiency.

Implementation Method 1

an optical lens... changes an output angle of light incident from a light emitting device that emits light to at least five surfaces

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

an light emitting module as disclosed has an improved luminance distribution at a central portion due to the bottom surface of the optical lens being inclined or curved... an absorption layer on a region of a circuit board where an amount of light reflected from the optical lens is the maximum

Methodology Applied

Scientific EffectAbsorption (EM radiation): Absorption (EM radiation)

Data Source

PatentEP3413112B1Optical lens and light emitting module having the same

Publication Date: 2020.12.23 SUZHOU LEKIN SEMICON CO LTD

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AI summary

Disclosed herein are an optical lens and a light emitting module having the same. The disclosed optical lens (300) includes a bottom surface (310), a recess (315) upwardly convex at a central region of the bottom surface, a light input surface (320) at a circumference of the recess, a first light output surface (320) having a convexly curved surface at opposite sides of the bottom surface and the light input surface, and a second light output surface (335) at a circumference of the first light output surface, wherein the bottom surface includes a first edge (23) adjacent to the recess and a second edge (25) adjacent to the second light output surface, a region of the bottom surface more adjacent to the first edge gradually approaches a first axis (X0) that is horizontal to a center of a bottom of the recess, and the first light output surface has a convex central region (32).