Light emitting device with self-aligning preformed lens

Patent metadata

Field	Value
Publication number	US-2016341852-A1
Application number	US-201515110840-A
Country	US
Kind code	A1
Filing date	Jan 4, 2015
Priority date	Jan 23, 2014
Publication date	Nov 24, 2016
Grant date	—

Abstract

A lens structure is pre-formed with features that facilitate accurate alignment of a light emitting chip within the lens structure. To ease manufacturing, the features include tapered walls that allow for easy insertion of the light emitting chip into the lens structure, the taper serving to accurately align the light emitting chip when the chip is fully inserted. The taper may include linearly sloped or curved walls, including complex shapes. An adhesive may be used to secure the light emitting chip to the lens structure. The light emitting chips may be picked-and-placed into an array of lens structures, or picked-and-placed onto a substrate that may be overlaid by the array of lens structures.

First claim

1 . A light emitting structure that includes:
a light emitting device, and a lens structure that includes:
a cavity within which the light emitting device is situated, the cavity having an opening and a taper such that a cross-section area within the cavity is smaller than an area of the opening, and
an optical element through which light emitted from the light emitting device is transmitted;
wherein the light emitting device is directly bonded to the lens structure without an intervening adhesive element.

2 . The lens structure of claim 1 , wherein the taper includes one or more walls that are linearly sloped.

3 . The lens structure of claim 2 , wherein at least one of the cross section areas of the cavity corresponds to a cross section area of light emitting device, so as to arrange the light emitting device at a fixed location within the lens structure.

4 . The lens structure of claim 1 , wherein a depth of the cavity is such that electrical contacts of the light emitting device protrude from the cavity.

5 . (canceled)

6 . The lens structure of claim 1 , wherein the taper includes one or more curved walls.

7 . The lens structure of claim 1 , including one or more channels that allow displacement of materials when the light emitting device is inserted in the cavity.

8 . The lens structure of claim 1 , including one or more protrusions within the cavity that serve to reduce the cross-section area.

9 . The lens structure of claim 1 , including a reflective material between an edge of the light emitting device and a wall of the cavity.

10 . A sheet comprising:
a plurality of light emitting elements that are situated in a plurality of lens structures formed of a silicone material, each lens structure having one or more tapered cavities for receiving the light emitting element and an optical element through which light that is emitted from the light emitting element is transmitted, wherein: each of the tapered cavities has an opening for receiving the light emitting element, a surface to which the light emitting element is optically coupled, and at least one cross section area that is less than a cross section area of the opening; and the silicone material is in a partially cured state when the plurality of light emitting elements is initially situated with the plurality of lens structures.

11 .- 13 . (canceled)

14 . A method for creating light emitting products, comprising:
providing a sheet that includes a plurality of lens structures, each lens structure having one or more tapered cavities for receiving a light emitting element and an optical element through which light emitted from the light emitting element is transmitted, and each of the tapered cavities has an opening for receiving the light emitting element, a surface to which the light emitting element is optically coupled, and at least one cross section area that is less than a cross section area of the opening; inserting a light emitting element into each of the tapered cavities; and singulating the lens structures with corresponding light emitting elements to form the light emitting product; wherein the lens structures comprise silicone that is in a partially cured state when the light emitting elements are inserted into the cavities, and the method includes curing the silicone after the light emitting elements are inserted into the cavities to bond the light emitting element to the lens structure without an intervening adhesive layer.

15 . (canceled)

16 . The method of claim 14 , wherein the lens structure includes one or more protrusions within the cavity that serve to reduce the cross-section area.

17 . The sheet of claim 13 , wherein the lens structure includes one or more protrusions within the cavity that serve to reduce the cross-section area.

18 . The sheet of claim 13 wherein a depth of the cavity is such that electrical contacts of the light emitting device protrude from the cavity.

19 . The light emitting structure of claim 1 , wherein the lens structure comprises a silicone material.

20 . The light emitting structure of claim 19 , wherein the light emitting device is bonded to the lens structure by a curing of the silicone material.

Assignees

• Koninklijke Philips Nv

Inventors

• Daeschner Walter
• Fouksman Mikhail
• Mala Mohiuddin
• Haque Ashim Shatil

Classifications

• H10W90/00

  Package configurations · CPC title

• F21V5/007

  Array of lenses or refractors for a cluster of light sources, e.g. for arrangement of multiple light sources in one plane (combination of two or more refractors F21V5/008) · CPC title

• G02B3/0075 Primary

  characterized by non-optical structures, e.g. having integrated holding or alignment means · CPC title

• G02B3/0056

  arranged along two different directions in a plane, e.g. honeycomb arrangement of lenses (G02B3/0043 takes precedence; miniaturised objectives for electronic devices employing wafer level optics G02B13/0085) · CPC title

• F21V17/101

  permanently, e.g. welding, gluing or riveting · CPC title