LED with Concave Base and Asymmetric Reflectors for Heat Management
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Solution Overview
Problem
Conventional backlight modules using densely arranged LEDs suffer from inefficient heat dissipation due to intense light output at central directions, leading to increased costs and reduced quality.
Innovation Solution
The LED design features a concave base with arc-shaped reflective layers, allowing for increased light emission at side directions, reducing the number of LEDs required and enhancing heat dissipation by spacing them further apart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are densely arranged to achieve sufficient light output, then illumination intensity is improved, but heat dissipation deteriorates and device complexity increases
Solution Approach 1:
The patent applies local quality by creating asymmetric light distribution through the concave base structure, where light is intentionally concentrated in specific side directions rather than uniformly in all directions. This allows sufficient illumination in target areas while reducing light output (and corresponding heat generation) in other directions, enabling sparser LED arrangement with effective illumination.
Solution Approach 2:
The patent transitions from considering only the horizontal arrangement density of LEDs to incorporating the angular distribution dimension. By controlling light emission patterns in different directions through the concave base geometry, the system achieves sufficient illumination with fewer LEDs spaced farther apart, resolving the contradiction between density and heat dissipation.
2Illumination intensity
If LEDs are densely arranged to achieve sufficient light output, then illumination intensity is improved, but manufacturing cost increases
Solution Approach 1:
By concentrating light output in specific side directions through the asymmetric concave base design, each LED becomes more efficient at delivering illumination to target areas. This reduces the total number of LEDs needed to achieve the required illumination intensity, lowering manufacturing costs while maintaining performance.
3Ease of manufacture
If conventional LED design with weak side light output is used, then manufacturing simplicity is maintained, but the number of LEDs required increases
Solution Approach 1:
The patent uses a concave base structure with specific curvature geometry to redirect and concentrate light output toward side directions. This geometric modification is integrated into the LED package design, maintaining manufacturability through standard molding processes while dramatically improving light distribution efficiency and reducing the quantity of LEDs required.
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 design results in reduced costs and improved heat dissipation, maintaining the quality of the backlight module while minimizing the number of LEDs needed.
Implementation Method 1
a reflective layer (15) attached on the concave (101) in the base (10)
Data Source
AI summary
An LED includes a base, an LED chip, a first electrode, a second electrode, an encapsulating layer, and a reflective layer. The base forms a concave recessed from a top face thereof and a recess above the concave. The reflective layer is attached on the concave. The LED chip is received in the recess and located over the reflective layer. The LED chip has a light output face facing towards the reflective layer. The encapsulating layer is filled in the recess to cover the reflective layer and encapsulate the LED chip. The reflective layer includes a first reflective layer and a second reflective layer. The first reflective layer is located at a center of the concave. The second reflective layer surrounds and connects the first reflective layer. The first reflective layer has a curvature smaller than that of the second reflective layer.