Central Silicone Module Gap for LED Optical Efficiency

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Solution Overview

Problem

Conventional lighting systems with LEDs lack efficient light distribution and optical efficiency due to the absence of a central silicone module that effectively receives and adjusts light characteristics, leading to suboptimal performance in strip lighting applications.

Innovation Solution

A lighting system comprising a circuit board with an LED, a central silicone module (CSM) constructed from reflective silicone, and a lens where the CSM holds the lens above the LED without contact with its lateral surface, forming a gap to enhance optical efficiency through total internal reflection and diffusive reflectivity, with the CSM optionally including titanium oxide particles for increased reflectance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a lens is held in direct contact with the CSM, then structural support is simplified, but optical efficiency decreases due to loss of total internal reflection

Engineering Contradiction:

Improvestructural supportVSAvoidoptical efficiency

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The patent segments the interaction between the lens and CSM by creating a gap that separates their contact surfaces. This segmentation allows the lateral surface of the lens to remain in contact with the CSM for structural support while the bottom surface is separated to enable total internal reflection, thus resolving the contradiction between simplified structure and optical efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary gap (filled with potting material or air) between the lens bottom surface and the CSM. This intermediary element enables the optical function of total internal reflection while still allowing the lens lateral surface to be supported by the CSM, thereby maintaining both structural simplicity and optical efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If conventional LED lighting systems are used without a central silicone module, then device complexity is reduced, but optical efficiency and light distribution performance deteriorate

Engineering Contradiction:

Improvedevice structureVSAvoidoptical efficiency

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The CSM serves multiple functions simultaneously: it provides structural support for the lens, acts as a reflector to redirect light, and enables total internal reflection through the gap it creates. This multi-functionality allows the system to achieve high optical efficiency without proportionally increasing device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses composite materials, specifically silicone rubber with high reflectivity properties (containing titanium dioxide particles), to create the CSM. This composite material combines structural flexibility with optical reflection capabilities, enabling the single component to perform multiple functions and improve overall system efficiency without adding significant complexity

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If the lens lateral surface is fully contacted by the CSM, then manufacturing precision is simplified, but light output and optical efficiency are reduced

Engineering Contradiction:

Improvelens positioningVSAvoidlight output

Core Design Contradiction:

Manufacturing precisionVSIllumination intensity

Solution Approach 1:

The patent applies local quality by differentiating the contact requirements of different lens surfaces. The lateral surface is designed to contact the CSM for positioning and support, while the bottom surface is designed to remain separated to enable total internal reflection. This localized differentiation of contact properties allows simplified manufacturing for positioning while preserving optical performance

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

The system achieves an optical efficiency of at least 88% by optimizing light output and temperature conditions, providing a robust and high-reflectance solution for strip lighting systems.

Implementation Method 1

a lens disposed over the LED and having a bottom surface facing the one side of the circuit board. The lens has a top surface opposite the bottom surface and a lateral surface between the top and bottom surfaces

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

forming a gap to enhance optical efficiency through total internal reflection

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 3

The central silicone module comprises a reflective silicone. For example, the reflective silicone may have a reflectance of at least 95% for visible light

Methodology Applied

Scientific EffectDiffusive reflection: Reflection