LED Lighting Device with Floating Scattering Volumes
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Solution Overview
Problem
Existing LED modules with scattering encapsulation require multiple process steps for light mixing, leading to inefficiencies and non-homogeneous light distribution due to the thickness and proximity of the scattering layer to the LED chips.
Innovation Solution
A potting compound with a light-transmissive, curable matrix material and scattering volumes of lower density than the matrix, which float and distribute inhomogeneously, allowing for efficient light mixing in a single step and adjustable concentration, enabling wide-angle light emission and homogeneous light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a scattering encapsulation layer is applied to achieve light mixing, then light mixing efficiency is improved, but the number of process steps increases and manufacturing complexity increases
Solution Approach 1:
The patent combines the scattering encapsulation and clear potting compound applications into a single potting step by incorporating scattering volumes directly into the potting compound. This merging of operations eliminates the need for separate scattering encapsulation and clear potting steps, reducing manufacturing complexity while maintaining light mixing efficiency.
Solution Approach 2:
The patent uses a composite potting compound that integrates scattering volumes within the matrix material. This composite material approach allows the scattering function to be built into the base material itself, eliminating the need for separate scattering encapsulation layers and simplifying the manufacturing process.
2Quantity of substance
If the scattering encapsulation is applied closer to the LED chips, then material usage is reduced, but light mixing efficiency deteriorates
Solution Approach 1:
The patent applies local quality by creating a non-uniform distribution of scattering volumes within the potting compound. The scattering volumes are concentrated closer to the LED chips where light mixing is most needed, while the concentration decreases toward the outer regions. This localized scattering approach maximizes light mixing efficiency with minimal material usage.
Solution Approach 2:
The patent changes the concentration parameter of scattering volumes as a function of distance from the LED chips. By varying the scattering volume concentration gradient, the system achieves optimal light mixing near the chips while reducing overall material usage compared to uniform distribution approaches.
3Illumination intensity
If multiple process steps are used for scattering encapsulation, then light mixing can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent merges the scattering encapsulation and clear potting operations into a single simultaneous process step. The potting compound containing scattering volumes is applied in one operation, eliminating the sequential steps required in conventional approaches and thereby increasing production speed without compromising light mixing quality.
Solution Approach 2:
The patent performs preliminary action by pre-mixing scattering volumes into the potting compound before application. This preparation ensures that the scattering function is already integrated into the material, allowing for single-step application and curing that achieves both light mixing and encapsulation simultaneously, improving productivity.
4Ease of manufacture
If a uniform concentration of scattering volumes is used, then material distribution is simplified, but light distribution homogeneity deteriorates
Solution Approach 1:
The patent implements local quality through a non-uniform concentration distribution of scattering volumes. The concentration varies spatially within the potting compound, with higher concentrations near the LED chips and lower concentrations toward the outer regions. This gradient distribution optimizes light mixing and achieves homogeneous light output by compensating for the inverse-square law of light propagation.
Solution Approach 2:
The patent transitions from uniform two-dimensional distribution to three-dimensional gradient distribution of scattering volumes. By controlling the concentration gradient in the vertical dimension (distance from LED chips), the system achieves superior light homogeneity that cannot be obtained with uniform planar distribution.
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 achieves effective light mixing and distribution with a single potting step, eliminating the need for multiple layers and ensuring consistent light emission across the LED module, particularly beneficial for LED chips with different spectral distributions.
Implementation Method 1
The scattering volumes have a lower density than the matrix material in its castable state. The scattering volumes therefore start to float or rise upward immediately after the potting.
Implementation Method 2
LED modules including a plurality of LED chips emitting light with a different spectral distribution may have a potting compound including scattering bodies contained therein for light mixing
Data Source
AI summary
The lighting device has at least one LED chip that is potted by means of a potting compound, which potting compound has a light-transmissive, castable and curable matrix material comprising scattering volumes as filler material, wherein the scattering volumes are distributed inhomogeneously over a thickness of the potting compound and these scattering volumes have a lower density than the matrix material in its castable state. A method is used for producing a lighting device, which comprises at least one LED chip, by means of at least the following steps: potting the at least one LED chip by means of a potting compound containing scattering volumes, wherein the scattering volumes have a lower density than a matrix material of the potting compound in this state; curing the potting compound so that an inhomogeneous distribution of the scattering volumes is obtained owing to floating of the scattering volumes in the matrix material.