LED Carrier Marking for Precise Placement Without Light Absorption
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Solution Overview
Problem
Lighting devices with light-mixing box optics suffer from reduced optical efficiency due to ink absorption of light emitted by LEDs, which is particularly pronounced in devices with small or narrow light-mixing boxes, and existing reflectors are difficult to design and often specific to the LED arrangement.
Innovation Solution
A method using a marking substance on the carrier that is either non-absorbing or modifiable by reaction, allowing precise placement of LEDs with surface-mount equipment, ensuring high optical efficiency by minimizing light absorption and enhancing reflectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If black ink is applied to the board for component placement markings, then the surface-mount equipment can detect component positions and orientations, but the ink absorbs light emitted by LEDs reducing optical efficiency
Solution Approach 1:
The patent changes the optical parameters of the marking substance by using materials with different absorption characteristics. Instead of traditional black ink that absorbs visible light, the patent uses marking substances that are transparent or reflective to LED wavelengths, thereby maintaining detection precision while minimizing light absorption and energy loss.
Solution Approach 2:
The patent applies color change principles by selecting marking substances with specific optical properties that differ from traditional black ink. The markings are designed to be visible to surface-mount equipment detection systems while being transparent or reflective to LED light wavelengths, thus resolving the contradiction between detectability and optical efficiency.
2Loss of energy
If special reflectors are designed to cover regions between LEDs with reflecting material, then optical efficiency is increased, but the device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent makes the carrier board universal by integrating marking functionality directly into the board surface. The marking substances used are multi-functional: they serve as placement guides for surface-mount equipment and simultaneously act as reflective or transparent surfaces that enhance optical efficiency. This eliminates the need for separate, complex reflector components designed for specific LED arrangements.
Solution Approach 2:
The patent extracts the reflector function from a separate component and integrates it into the carrier board markings themselves. By applying marking substances with reflective or transparent properties directly to the board, the patent eliminates the need for additional reflector parts, thereby reducing device complexity and manufacturing difficulty while maintaining optical efficiency.
3Area of stationary object
If LEDs are required to be very closely spaced on the board, then the lighting device becomes more compact, but it becomes impossible to design reflectors that cover regions between LEDs
Solution Approach 1:
The patent changes the approach by using marking substances applied directly to the board surface in the spaces between closely spaced LEDs. This method is feasible for high-density LED arrangements where traditional reflectors would be impossible to manufacture, as the marking process can accommodate very small spaces between components.
Solution Approach 2:
The patent applies local quality by selectively placing marking substances only in the regions between LEDs where reflection or transparency is needed. This localized application is particularly effective for closely spaced LEDs, as it targets specific areas without requiring complex overall reflector structures that would be difficult to manufacture for high-density arrangements.
4Measurement precision
If traditional black ink is used for markings, then component placement detection is achieved, but light absorption occurs reducing the reflectivity of the mixing box
Solution Approach 1:
The patent changes the optical parameters of the marking substance by selecting materials with different absorption coefficients. Instead of black ink that absorbs LED wavelengths, the patent uses marking substances that are transparent or reflective to LED light while remaining detectable by surface-mount equipment, thereby eliminating the harmful light absorption effect.
Solution Approach 2:
The patent converts the potentially harmful light absorption property into a beneficial reflective or transparent property. By selecting marking substances with appropriate optical characteristics, the markings that were originally harmful (absorbing LED light) become beneficial (reflecting or transmitting light), thus improving mixing box reflectivity while maintaining detection accuracy.
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 method ensures high optical efficiency and thermal performance by accurately positioning LEDs without significant light absorption, using a marking substance that is either non-absorbing or becomes reflective, thus optimizing light emission.
Implementation Method 1
the ink or ink composition that does not absorb visible light or at least not light having a wavelength within the selected wavelength range
Implementation Method 2
the ink or ink composition that is modifiable by a reaction, which reaction is caused by at least one of use of the lighting device or the making of the lighting device, such that the ink or ink composition vanishes or becomes reflective for visible light
Data Source
AI summary
A method (200) for making a lighting device is provided. The lighting device comprises a carrier having a side on which lighting elements are to be mounted in a selected arrangement in relation to each other using the surface-mount equipment. The method comprises marking (201) on the side of the carrier, using a marking substance comprising an ink composition, indications of the positions on the side of the carrier where the lighting elements are to be placed in order for the lighting elements to become mounted on the side of the carrier according to the selected arrangement of the lighting elements in relation to each other, wherein at least one of the surface-mount equipment or the marking substance is arranged such that the marking substance is detectable by the surface-mount equipment. Using the surface-mount equipment and based on the indications marked on the side of the carrier, the lighting elements are placed (204) on the side of the carrier so that the lighting elements become mounted on the side of the carrier in accordance with the selected arrangement of the lighting elements in relation to each other.