LED Device Holder Fillet Geometry for Efficient Secondary Optics
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Solution Overview
Problem
Traditional secondary optical elements in LED systems using COB LED devices reduce efficiency, and there is a need for improved secondary optics that enhance the performance of LED lighting systems.
Innovation Solution
The implementation of an LED device holder with a fillet-shaped aperture and a reflector system, where the fillet radius is optimized to enhance light distribution and efficiency, using materials like polybutylene terephthalate glass and aluminum reflectors to concentrate and direct light effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional secondary optical elements are used in LED systems, then the structure is simple and easy to manufacture, but the system efficiency is reduced
Solution Approach 1:
The patent applies curvature by implementing a fillet (rounded corner) at the aperture edge of the holder instead of a sharp 90-degree corner. This curved geometric feature optimizes light distribution and increases system efficiency by reducing light loss while maintaining structural integrity and manufacturability
Solution Approach 2:
The patent changes the geometric parameter of the aperture by specifying a fillet radius between 0.5mm and 2.0mm. This parameter optimization improves light extraction efficiency and system performance without fundamentally changing the overall device structure or manufacturing process
2Productivity
If a fillet with radius 0.5mm to 2.0mm is implemented, then light distribution and efficiency are enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes the fillet radius parameter to a specific range (0.5mm to 2.0mm) that balances performance improvement with manufacturing feasibility. This parameter selection achieves enhanced light distribution while remaining compatible with standard manufacturing capabilities
Solution Approach 2:
The fillet geometry naturally forms through standard molding or machining processes without requiring additional complex manufacturing steps. The rounded corner is self-generated during normal production, reducing the need for specialized high-precision manufacturing equipment or processes
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 optimized fillet radius increases the efficiency of LED lighting systems by up to 8%, improving flux, maximum intensity, and full width at half maximum, while maintaining a focused beam pattern.
Implementation Method 1
a reflector positioned at the rear of the LED array... reflecting light emitted from the LED array
Implementation Method 2
The aperture has a perimeter and a fillet adjacent the perimeter. The fillet has a radius greater than or equal to 2.0 mm and less than or equal to 4.6 mm
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
An LED device holder (300), an LED lighting system and a method of manufacturing an LED lighting system are described herein. An LED lighting system includes a holder (300) defining an aperture. The aperture has a perimeter and a fillet adjacent the perimeter. The fillet has a radius (316) greater than or equal to 2.0 mm and less than or equal to 4.6 mm. An LED array is mechanically coupled to the holder (300). The LED array has a light emitting surface exposed through the aperture.