Non-Rectangular LED Emission Surfaces for Optical Aperture Matching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional light-emitting diodes (LEDs) with rectangular emission surfaces are not optimized for use in optical systems with circular or non-rectangular input apertures, leading to inefficiencies in light transmission and increased etendue, which limits the extent to which narrow beams of light can be projected.
Innovation Solution
The emission surface of the LED is shaped to match the input aperture, either through the use of non-rectangular polygonal emission surfaces or emitter output apertures, such as circular or pentagonal shapes, to enhance optical and thermal efficiencies by ensuring that a larger amount of light is transmitted while preserving the etendue of the source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular emission surface is used in conventional LEDs, then the manufacturing process is simple, but the light transmission efficiency is reduced when used with circular or non-rectangular input apertures
Solution Approach 1:
The patent changes the geometric parameter of the emission surface from rectangular to non-rectangular (circular, polygonal, or irregular shapes) to match the input aperture geometry. This parameter change optimizes light transmission efficiency by eliminating wasted light from corners that cannot pass through circular apertures, while the manufacturing process remains compatible with standard LED fabrication techniques.
2Loss of energy
If the emission surface shape is changed to match the input aperture, then the optical efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent applies local quality by modifying only the emission surface geometry at the light-output interface while keeping the internal LED structure and manufacturing processes standard. This localized change optimizes optical coupling efficiency without requiring complex modifications throughout the entire device, thus improving optical efficiency with minimal increase in overall device complexity.
3Area of stationary object
If a rectangular emission surface is used, then the etendue is increased, but the beam narrowness is limited
Solution Approach 1:
The patent employs curved geometries (circular or polygonal emission surfaces) instead of rectangular shapes to better match the circular input aperture of optical systems. This curved geometry reduces the etendue by eliminating corner regions that contribute to beam divergence, thereby enabling narrower beam projection while maintaining effective light transmission through the aperture.
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 approach increases the lumens per etendue of the system, reduces light loss, and allows for more efficient heat dissipation, thereby improving the overall performance and efficacy of LED-based optical systems.
Implementation Method 1
A light-emitting diode (LED) often can provide light in a more efficient manner than an incandescent light source and/or a fluorescent light source
Implementation Method 2
During use, electrical energy is usually injected into an LED and then converted into electromagnetic radiation (light)
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
The present invention relates to light-emitting diodes (LEDs), and related components, processes, systems, and methods. In certain embodiments, an LED that provides improved optical and thermal efficiency when used in optical systems with a non-rectangular input aperture (e.g., a circular aperture) is described. In some embodiments, the emission surface of the LED and/or an emitter output aperture can be shaped (e.g., in a non-rectangular shape) such that enhanced optical and thermal efficiencies are achieved. In addition, in some embodiments, chip designs and processes that may be employed in order to produce such devices are described.