Asymmetric Reflector Cup for LED Light Direction
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Solution Overview
Problem
Conventional large format LED displays waste a significant amount of light due to their elevated mounting, leading to inefficiency and light pollution, as much of the emitted light is not visible to viewers and causes unwanted reflections and glare.
Innovation Solution
The use of LED packages with a reflector cup having a bottom surface and a wall surface inclined relative to the bottom surface, which directs light emission towards the viewer's line of sight, reducing waste and pollution by optimizing the light distribution and reducing the need for complex mounting hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If LED displays are mounted at elevated positions, then visibility coverage area is improved, but light waste and light pollution increase
Solution Approach 1:
The reflector cup employs an asymmetric geometry with a non-uniform cross-section along its height. The cross-sectional area varies continuously from the base to the apex, creating different reflection angles for light rays depending on their origin point. This asymmetric structure directs light preferentially toward lower viewing angles, matching the typical viewer position while minimizing upward light waste, thus resolving the contradiction between coverage area and energy loss.
Solution Approach 2:
The reflector cup's cross-sectional area is locally optimized at different heights. The upper portion has a smaller cross-sectional area compared to the base, creating a tapered structure. This local variation in geometry allows the reflector to concentrate and redirect light toward specific viewing zones (lower angles) while reducing light emission in unwanted directions (upward and horizontal), thereby decreasing light waste without compromising visibility coverage.
2Loss of energy
If display mounting angle is adjusted to match viewer's line of sight, then light efficiency is improved, but mounting hardware complexity increases
Solution Approach 1:
The patent extracts the light direction control function from the mounting hardware and integrates it directly into the LED package structure through the reflector cup. Instead of requiring complex angled mounting brackets or adjustable mechanisms, the reflector cup's asymmetric geometry inherently directs light at the desired angles. This extraction of the directional control function from the mounting system simplifies the overall hardware complexity while maintaining high light efficiency.
Solution Approach 2:
The reflector cup serves multiple functions simultaneously: it reflects and redirects light, defines the beam pattern, and provides structural support for the LED chip. By integrating these functions into a single component within the LED package, the design eliminates the need for separate mounting hardware to achieve proper light direction, thereby reducing overall system complexity while maintaining optimal light efficiency.
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 solution enhances the efficiency of light emission from LED displays, reduces energy consumption, and minimizes light pollution by directing light towards the viewer, thereby improving the overall performance and visibility of large format LED displays.
Implementation Method 1
reflector cup having a bottom surface and a wall surface inclined relative to the bottom surface
Data Source
AI summary
An LED package and a lead frame include a reflector cup having a bottom surface with an LED asymmetrically positioned on the bottom surface and a wall surface inclined relative to the bottom surface and defining an opening at an upper end thereof. The bottom surface of the reflector cup has a first axial dimension along a first axis and a second axial dimension along a second axis, orthogonal to the first axis. A display having an asymmetrical FFP and asymmetrical screen curve includes an array of the LED modules including a plurality of LED packages. At least some of the LED packages include a dome-shaped lens asymmetrically positioned with respect to a geometric center of the bottom surface of the reflector cup.