LED Beam Shaping Layer and Refracting Layer for Light Directionality
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Solution Overview
Problem
Conventional light emitting diodes (LEDs) emit light in a non-directional, lambertian profile, requiring costly and complex secondary optics to focus the light, which increases the size of the LED package and is inefficient.
Innovation Solution
An integrated multi-layer apparatus is developed, comprising an LED with a beam shaping layer and a refracting layer of lower index of refraction, where the beam shaping layer passes focused light and reflects non-focused light back to the LED, which is then randomly scattered and redirected, eliminating the need for external secondary optics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If secondary optics are used to focus light from LED, then light directionality is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple optical functions (beam shaping, light recycling, and focusing) into a single integrated multi-layer apparatus. The beam shaping layer and refracting layer work together as one unit to achieve light directionality control without requiring separate secondary optics, thereby reducing device complexity while maintaining illumination intensity.
Solution Approach 2:
The LED structure incorporates light recycling mechanisms where the refracting layer redirects light that would otherwise be lost back into the LED chip. This self-service approach allows the system to improve its own light extraction efficiency without external optical components, reducing the need for additional focusing optics.
2Illumination intensity
If secondary optics are used to shape light emission, then light focusing is improved, but package size increases
Solution Approach 1:
The patent merges the light shaping function directly into the LED package structure through the beam shaping layer and refracting layer. This integration eliminates the need for external secondary optics, achieving light focusing while minimizing package size expansion.
Solution Approach 2:
The optical layers are nested within the LED package structure itself. The refracting layer is positioned between the LED chip and the beam shaping layer, creating a compact nested arrangement that achieves light focusing without adding significant package volume.
3Quantity of substance
If light is emitted in all directions, then light output quantity is maximized, but light utilization efficiency decreases
Solution Approach 1:
The refracting layer creates a feedback mechanism by redirecting light that exits at unfavorable angles back into the LED chip. This feedback loop allows the system to recover and reuse light that would otherwise be lost, improving light utilization efficiency while maintaining total light output through multiple extraction opportunities.
Solution Approach 2:
The patent recovers light that would normally be discarded (emitted at angles outside the escape cone). The refracting layer captures this discarded light and redirects it back into the LED, where it can be scattered and potentially extracted on subsequent attempts, thereby recovering energy that would otherwise be wasted.
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 light emission efficiency by recycling light within the LED, reducing the need for external optics and minimizing package size while improving brightness and adaptability across various applications.
Implementation Method 1
a refracting layer between the beam shaping layer and the LED, the refracting layer having an index of refraction lower than the index of refraction of the LED and the beam shaping layer
Implementation Method 2
a beam shaping layer configured to pass the first portion of the emitted light and reflect the second portion of the emitted light back to the LED
Implementation Method 3
the LED is further configured to randomly scatter the second portion of the emitted light reflected by the beam shaping layer
Data Source
AI summary
An integrated multi-layer apparatus and method of producing the same is disclosed. The apparatus comprises an LED, a beam shaping layer, and a refracting layer between the beam shaping layer from the LED. The refracting layer may have an index of refraction lower than the index of refraction of the LED and the beam shaping layer.