Resin Lens Structure for Narrow-Beam Semiconductor LEDs
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Solution Overview
Problem
Existing semiconductor light emitting devices face challenges in achieving high forward emitted light intensity with narrow light distribution characteristics due to misalignment and positional deviations between the light emitting element and the lens, leading to suboptimal light distribution.
Innovation Solution
A semiconductor light emitting device with a resin lens is designed, featuring a circular ring-shaped metal ring body and regulation holes on a substrate, where the lens is formed by embedding the semiconductor light emitting element and condensing light, with a spheroid-shaped top surface to enhance directivity and reduce positional and optical axis deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a lens is formed by injecting resin, then the lens can be manufactured with simple process, but the forward emitted light intensity is reduced and light distribution characteristics become wide
Solution Approach 1:
The patent applies spheroidality by forming the lens top surface as a spheroid shape with a specific curvature radius (R1) that is 0.05 to 0.15 times the outer diameter of the metal ring body. This curved spheroidal surface optimizes light condensation and directs light forward, resolving the contradiction by achieving both narrow light distribution and high forward intensity through geometric curvature rather than complex molding processes.
Solution Approach 2:
The patent changes the geometric parameters of the lens, specifically setting the curvature radius R1 within the range of 0.05 to 0.15 times the outer diameter of the metal ring body, and controlling the height H1 to be 0.2 to 0.4 times the outer diameter. These parameter optimizations enable the lens to achieve narrow light distribution and high forward intensity while maintaining the simple resin injection manufacturing process.
2Ease of manufacture
If resin injection molding is used for lens formation, then manufacturing is simplified, but positional deviation and optical axis misalignment occur between lens and light emitting element
Solution Approach 1:
The patent applies self-service by designing the mold structure to automatically self-align during the resin injection process. The mold includes a lower mold with a recess and an upper mold that fits onto it, with the light emitting element positioned in the recess before resin injection. This self-aligning mechanism ensures that the lens forms precisely aligned with the light emitting element without requiring complex external alignment equipment, thus achieving both simple manufacturing and high positional precision.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the light emitting element and regulating holes on the substrate before the resin injection process. The element position is predetermined and fixed, and the regulation holes are pre-formed at specific positions. During resin injection, the resin flows around these pre-positioned features, automatically forming the lens with correct alignment. This preliminary positioning ensures manufacturing precision while keeping the overall process simple.
3Device complexity
If a simple lens structure is used, then device complexity is reduced, but light distribution accuracy deteriorates
Solution Approach 1:
The patent uses a spheroidal lens surface with optimized curvature radius to achieve accurate light distribution without complex internal structures. The simple yet precisely curved surface geometry enables controlled light condensation and directional emission, maintaining low device complexity while achieving high light distribution accuracy through geometric optics principles.
Solution Approach 2:
The patent achieves accurate light distribution by optimizing geometric parameters of the simple lens structure. The curvature radius R1 is set to 0.05-0.15 times the outer diameter of the metal ring body, and height H1 is set to 0.2-0.4 times the outer diameter. These parameter optimizations enable the simple lens to achieve precise light distribution control without adding structural complexity.
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 solution results in a device with improved directivity characteristics and increased forward light intensity, along with highly accurate light distribution, while minimizing positional and optical axis deviations, thus achieving a semiconductor light emitting device with enhanced performance.
Implementation Method 1
a lens formed of a resin which embeds the semiconductor light emitting element and condenses light emitted from the semiconductor light emitting element
Data Source
Figure 1~2A
Figure 2B~2D
Figure 3A~4A
AI summary
A semiconductor light emitting device includes a plane substrate having a flat substrate surface, a semiconductor light emitting element mounted on the substrate surface, and a lens formed of a resin which embeds the semiconductor light emitting element and condenses light emitted from the semiconductor light emitting element. A circular ring-shaped metal ring body surrounding the semiconductor light emitting element, and a plurality of regulation holes arranged inside the metal ring body at positions rotationally symmetric with respect to the center of the metal ring body are provided on the substrate surface. A bottom of the lens is defined by the metal ring body and the regulation holes. A body part of the lens has a plurality of valley portions extending toward the top of the lens from the positions of the regulation holes. The top of the lens has a surface as a spheroid surface with an axis vertical to the substrate surface and passing through the center of the metal ring body as a major axis.