LED Module Reflective Carrier with Ceramic Lacquer
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Solution Overview
Problem
Existing LED modules face inefficiencies due to suboptimal reflectance and complex constructions, particularly with reflective layers and heat dissipation issues.
Innovation Solution
An LED module design featuring a metallic layer on a carrier with a ceramic lacquer layer that provides double reflection and improved thermal conductivity, along with a dam and central filling for enhanced light distribution and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a reflective layer is applied on the carrier in regions where no LED chips are present, then light reflectance is improved, but the efficiency of the module is reduced due to incomplete reflection
Solution Approach 1:
The patent applies a composite structure consisting of a metallic layer (silver or aluminum) combined with a ceramic lacquer layer. The metallic layer provides high reflectance while the ceramic lacquer protects against oxidation and maintains reflection properties over time, creating a composite reflective system that resolves the efficiency loss problem
2Illumination intensity
If a reflective layer is applied on the carrier, then light reflectance is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The patent implements local quality by applying the metallic layer selectively in regions where no LED chips are present, while maintaining thermal conductivity pathways. The ceramic lacquer layer is applied specifically to protect the metallic layer's reflective properties without compromising heat dissipation, creating localized functional zones
3Illumination intensity
If a complex multi-layer structure with scattering layer and phosphor layer is applied, then light distribution is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates unnecessary layers from the conventional multi-layer structure. By using the ceramic lacquer layer to simultaneously provide protection, reflectance enhancement, and light distribution, the design removes the need for separate scattering layers and phosphor layers, thereby reducing device complexity while maintaining improved light 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
The design significantly increases light reflectance and thermal efficiency, maintaining high performance even with oxidative blackening of the metal layer, while simplifying the module's construction and enhancing light homogeneity.
Implementation Method 1
the light from the LED chip that passes through the lacquer layer can be reflected back on account of the underlying metallic layer
Implementation Method 2
the thermal conductivity of the module is improved by the use of the metal layer according to the invention
Data Source
AI summary
An LED module, including a carrier having high reflectivity, wherein a metal layer, preferably a silver layer or a layer of high-purity aluminum, is applied to the carrier. Also disclosed is an LED module, including a carrier having high reflectivity, wherein a metal layer is applied to the carrier, at least one LED chip, and a dam, wherein the metal layer partially covers the surface of the carrier lying under the dam.