Integrated Photoluminescence Wavelength Conversion Component

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Solution Overview

Problem

The existing configuration of white LEDs with separate wavelength conversion and reflective components requires additional assembly steps, incurs significant material and administrative costs, and suffers from light loss due to blocking by mounting portions, leading to reduced lighting efficiency.

Innovation Solution

An integrated photoluminescence wavelength conversion component that combines a photoluminescence material portion with a reflective material portion, optionally including a light diffusive material, is manufactured as a single unit, eliminating the need for separate assembly and reducing material costs and light loss by optimizing the reflector configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If separate wavelength conversion component and reflective material are used, then light reflection efficiency can be improved, but device complexity and assembly cost increase

Engineering Contradiction:

Improvelight reflection efficiencyVSAvoidassembly complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent combines the wavelength conversion component and reflective material into a single integrated component. The reflective material is applied to the base portion of the wavelength conversion component, creating a unified structure that performs both wavelength conversion and light reflection functions simultaneously, eliminating the need for separate assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated component serves multiple functions: it converts light wavelength through photoluminescent materials while simultaneously reflecting light through the integrated reflective material. This multi-functional design reduces the number of components needed and simplifies the overall device structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If separate reflective material is added to base, then light emission efficiency improves, but manufacturing cost increases

Engineering Contradiction:

Improvelight emission efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The reflective material is integrated directly into the wavelength conversion component structure, eliminating the need for separate procurement and assembly of reflective materials. This consolidation reduces material costs and simplifies the manufacturing supply chain.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The wavelength conversion component is designed to be self-sufficient by incorporating its own reflective material, eliminating the need for external reflective components. The component serves its own light management needs through the integrated reflective surface.

Inventive Principle:

Principle #25Self-service

3Device complexity

If mounting portion blocks light from lower levels, then assembly simplicity is maintained, but light loss increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidlight loss

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The reflective material is applied to the bottom surface of the wavelength conversion component, utilizing the vertical dimension to redirect light that would otherwise be blocked. This allows light from lower levels to be reflected outward through the side surfaces, effectively using space in a different dimension to solve the blocking problem.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The mounting portion structure that previously caused light blocking is now utilized as a base for applying reflective material. The same structural element that caused the problem is transformed into part of the solution by serving as the substrate for the reflective coating, converting the harmful blocking effect into a beneficial light redirection mechanism.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 integrated approach reduces manufacturing costs, minimizes damage to reflective surfaces, and enhances light conversion efficiencies by ensuring that light from the wavelength conversion layer is effectively reflected outward, thereby improving the overall lighting performance.

Implementation Method 1

The phosphor materials within the photoluminescence layer 106 generate photoluminescence light in response to excitation light emitted by an LED die 110

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Implementation Method 2

the reflective material 114 is necessary to make sure that the light emitted in the downwards direction is not wasted, but is instead reflected to be emitted outwardly

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9512970B2Photoluminescence wavelength conversion components

Publication Date: 2016.12.06 INTEMATIX CORP

AI summary

A photoluminescence wavelength conversion component comprises a first portion having at least one photoluminescence material; and a second portion comprising light reflective material, wherein the first portion is integrated with the second portion to form the photoluminescence wavelength conversion component.