COB LED Light Cover with Total Reflection Slope for Uniform Illumination
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Solution Overview
Problem
The existing illumination systems for power tools using chip-on-board light emitting diodes (COB LEDs) suffer from non-uniform illuminance distribution and light loss, which affects the efficiency and comfort of work illumination.
Innovation Solution
The implementation of a light cover with a circular ring substrate and an inner cylindrical portion that includes a cover slope to totally reflect light from the LED chip, reducing light loss and ensuring uniform illuminance distribution, along with an illuminance sensor and LED control circuit to adjust light output based on reflected light levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a chip-on-board light emitting diode is used to illuminate the work target, then a higher amount of light is emitted and the work space is brightly illuminated, but the illuminance distribution becomes non-uniform and light loss increases
Solution Approach 1:
A light cover is introduced as an intermediary component between the COB LED and the work target. The light cover includes a light transmission portion and an inner cylindrical portion with a cover slope that totally reflects light forward, mediating the light distribution to achieve uniform illuminance while maintaining high light output
Solution Approach 2:
The light cover is divided into functional segments: a light transmission portion for direct light passage and an inner cylindrical portion with cover slope for total reflection. This segmentation allows different regions to optimize light transmission and reflection separately, achieving uniform illuminance distribution
2Illumination intensity
If a chip-on-board light emitting diode is used to illuminate the work target, then a higher amount of light is emitted, but light loss increases
Solution Approach 1:
The cover slope in the inner cylindrical portion converts potentially lost light (harm) into useful forward-directed light (benefit) through total reflection. This transforms light that would otherwise be wasted into effective illumination, reducing overall light loss while maintaining high light output
3Illumination intensity
If light is emitted with high intensity to brightly illuminate the work space, then the work space is well-lit, but worker discomfort from excessive glare increases
Solution Approach 1:
The light cover creates different light transmission qualities in different regions: the light transmission portion allows direct light passage while the cover slope portion provides total reflection. This local differentiation of light quality achieves uniform illuminance distribution that prevents glare while maintaining overall brightness
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 configuration enhances the irradiation state of the COB LED by minimizing light loss and providing appropriate illuminance, preventing worker discomfort from excessive glare and ensuring uniform illumination of the work target.
Implementation Method 1
The inner cylindrical portion may include a cover slope that totally reflects light from the LED chip forward
Data Source
AI summary
A power tool includes a motor, an output shaft, a chip-on-board light emitting diode, and a light cover. The output shaft is rotated by a rotational force of the motor. The chip-on-board light emitting diode is disposed around the output shaft. The chip-on-board light emitting diode includes: a substrate having a circular ring portion; and an LED chip disposed on a front surface of the circular ring portion. The light cover is fixed to the substrate. The light cover includes: an inner cylindrical portion disposed radially inside with respect to the circular ring portion; and a light transmission portion through which light emitted from the LED chip passes. The inner cylindrical portion includes a cover slope that totally reflects light from the LED chip forward.