LED Light Shade with Etched Reflecting Layer
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Solution Overview
Problem
Conventional light emitting diodes (LEDs) face issues with non-uniform distribution of fluorescent powder, leading to reduced brightness and light-emitting efficiency, and are prone to yellowing due to epoxy resin-based light shades, which shortens their lifespan and weakens light output.
Innovation Solution
A light emitting diode structure featuring a glass or quartz light shade with a uniform fluorescent powder layer on top and a reflecting etched layer on lateral walls, where the walls are treated with hydrofluoric acid to create irregular depressions and lumps, enhancing reflectivity and light gathering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If light shades are made of epoxy resin mixed with fluorescent powder, then manufacturing is easier and cost is lower, but fluorescent powder distribution becomes non-uniform and yellowing occurs
Solution Approach 1:
The patent replaces epoxy resin with glass or quartz as the base material for the light shade. These materials provide a stable, non-yellowing substrate that allows for uniform fluorescent powder distribution while maintaining ease of manufacturing through established glassworking and quartz-forming processes
Solution Approach 2:
The patent changes the fundamental material parameter from organic epoxy resin to inorganic glass/quartz. This parameter change eliminates the yellowing issue inherent in epoxy resin while providing a stable surface for uniform fluorescent powder application, resolving both the manufacturing precision problem and the aging problem
2Ease of manufacture
If light shades are made of epoxy resin mixed with fluorescent powder, then manufacturing is easier and cost is lower, but light shade yellows over time reducing brightness
Solution Approach 1:
The patent uses glass or quartz as the base material combined with fluorescent powder coating. This composite structure provides resistance to yellowing while maintaining ease of manufacture through standard glass and quartz processing techniques, thereby preserving brightness over time
Solution Approach 2:
By changing the base material from epoxy resin to glass or quartz, the patent eliminates the chemical degradation that causes yellowing. This parameter change ensures long-term brightness maintenance while keeping manufacturing feasible through established inorganic material processing methods
3Illumination intensity
If lateral wall portions are etched with hydrofluoric acid to create irregular surfaces, then reflectivity increases and brightness improves, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical surface structuring with a chemical etching process using hydrofluoric acid. This chemical approach creates the desired irregular surface morphology for enhanced light reflection through a simpler, more controllable process compared to mechanical methods
Solution Approach 2:
The patent changes the surface treatment method from mechanical to chemical by using hydrofluoric acid etching. This parameter change simplifies the manufacturing process while achieving the same or better surface irregularity for light reflection, thereby improving brightness without significantly increasing manufacturing complexity
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 ensures uniform fluorescent powder distribution, increases brightness, and prevents yellowing, thereby enhancing the light-emitting efficiency and longevity of LEDs.
Implementation Method 1
the light shade has a fluorescent powder layer on a top for changing color of light
Implementation Method 2
the light shade has a reflecting layer on lateral wall portions for reflecting light produced by the light emitting diodes
Implementation Method 3
the lateral wall portions of the light shade are soaked in and etched with hydrofluoric acid so as to have irregular depressions and lumps on the surfaces to increase reflectivity of the reflecting layer
Data Source
AI summary
A light emitting diode includes a base board, at least one light emitting diodes fitted on an upper side of the base board, and a light shade made of either of glass and quartz, which is secured over said at least one light emitting diodes on the base board; the light shade has a fluorescent powder layer on a top thereof for changing color of light; the light shade has a reflecting layer on lateral wall portions thereof for reflecting light produced by the light emitting diodes such that light gathers at the top of the light shade to be brighter; furthermore, in manufacturing, the lateral wall portions of the light shade are soaked in and etched with hydrofluoric acid so as to have irregular depressions and lumps on the surfaces to enhance reflectivity of the reflecting layer.