LED Light-Blocking Cover Structure for Directional Illumination

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Solution Overview

Problem

Existing illumination units face challenges in achieving appropriate light output and manufacturing efficiency due to light leakage and potential contact between the light source unit and the cover during assembly.

Innovation Solution

The illumination unit incorporates a substrate with a light-emitting element, a housing, a case, and a light-blocking cover that surrounds the light-emitting element but does not cover it in the direction of light output, ensuring proper light direction and protecting the element during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the light source unit is provided inside the cover to output light, then the illumination function is achieved, but light may leak from the cover in an unintended direction and appropriate light output is difficult

Engineering Contradiction:

Improvelight output directionalityVSAvoidcover structure complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The cover is divided into a light transmission cover and an illumination cover, with the illumination cover further segmented into a light-blocking cover and a light transmission cover. This segmentation allows different portions of the cover to perform different functions: blocking light in unintended directions while transmitting light in the desired illumination direction, thereby achieving directional light control without excessive overall complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cover have different optical properties. The light-blocking cover portion blocks light in unintended directions, while the light transmission cover portion allows light to pass through in the desired direction. This local differentiation of optical quality enables precise light directionality control.

Inventive Principle:

Principle #3Local quality

2Reliability

If the cover is attached to cover the light source unit, then protection and structural integrity are achieved, but the cover may come into contact with the light source unit during manufacturing

Engineering Contradiction:

Improveprotection of light source unitVSAvoidassembly process difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The illumination cover is preliminarily formed with a protrusion that fits into a corresponding recess in the housing. This preliminary structural arrangement ensures proper positioning and spacing between the cover and light source unit before final assembly, preventing contact during manufacturing while maintaining protection and structural integrity.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If a simple cover structure is used, then manufacturing is easier, but light leakage in unintended directions occurs

Engineering Contradiction:

Improvecover manufacturing simplicityVSAvoidlight leakage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The cover is segmented into light-blocking and light transmission portions, allowing the structure to address light leakage without requiring a completely complex design. Each segment performs a specific function, maintaining relative manufacturing simplicity while effectively controlling light direction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover incorporates local light-blocking portions and light transmission portions with different optical properties. This local quality differentiation prevents light leakage in unintended directions while maintaining overall structural simplicity and ease of manufacture.

Inventive Principle:

Principle #3Local quality

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 allows for effective light output in the desired direction while preventing accidental contact between the case and the light-emitting element during manufacturing, ensuring proper assembly and enhanced illumination performance.

Implementation Method 1

a light-emitting element mounted on a substrate

Methodology Applied

Scientific EffectLight emission: Light Emitting Diode

Implementation Method 2

a light-blocking cover that is attached to the substrate, surrounds the light-emitting element and leaves the light-emitting element in a direction in which the light is output uncovered

Methodology Applied

Scientific EffectLight blocking: Absorption (EM radiation)

Data Source

PatentUS12237625B2Illumination unit

Publication Date: 2025.02.25 YAZAKI CORP

AI summary

An illumination unit includes: a substrate to which a first light-emitting element is mounted; a housing that holds the substrate; a case that is attached to the housing so as to cover the substrate and can output light of the first light-emitting element to the outside; and a light-blocking cover that is attached to the substrate, is provided so as not to cover the first light-emitting element in a direction in which light is output while surrounding the first light-emitting element, and is formed higher from a front face of the substrate than the first light-emitting element.