LED Module Encapsulation via Uncured Layer Merging
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Solution Overview
Problem
Existing LED modules with multilayer encapsulation suffer from light losses and color fluctuations due to phase boundaries and adhesive layers, leading to unsatisfactory light homogeneity and decoupling efficiency, which are exacerbated by complex and costly manufacturing processes.
Innovation Solution
A method involving a hollow housing with a transparent base layer and a scattering layer, where the scattering layer is applied to the uncured base layer, eliminating the need for adhesive layers and allowing for precise adjustment of layer thickness and curvature to enhance light homogeneity and decoupling efficiency without phase boundaries, using materials with matching refractive indices and thermal expansion coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thick scattering matrix material is used to homogenize light, then light homogeneity is improved, but light losses increase
Solution Approach 1:
The scattering matrix material is divided into multiple discrete scattering elements distributed throughout the housing, rather than using a single thick layer. This segmentation allows light to be scattered progressively as it travels through the housing, achieving homogeneity with reduced total scattering thickness and associated light losses.
2Loss of energy
If a transparent layer with a thinner spreader is used, then light losses are reduced, but phase boundaries cause light reflection
Solution Approach 1:
The transparent matrix material and scattering elements are merged into a single integrated housing structure. The scattering elements are distributed within the transparent material rather than being separate layers, eliminating phase boundaries and adhesive layers that cause light reflection while maintaining the optical functionality of both components.
3Stability of the object's composition
If multiple layers with adhesive layers are used, then light homogeneity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple functional layers (transparent matrix, scattering layer, adhesive layers) are merged into a single integrated housing structure. The scattering elements are distributed within the transparent material during a single manufacturing process, eliminating the need for separate layer application and adhesive bonding steps, thereby reducing manufacturing complexity and cost.
4Stability of the object's composition
If adhesive layers are used to fix layers, then layer stability is improved, but delaminations occur over time due to thermal expansion
Solution Approach 1:
The transparent matrix material and scattering elements are merged into a single integrated structure without adhesive layers. This eliminates the interface between different materials that has different thermal expansion coefficients, preventing delamination caused by thermal stress while maintaining the structural stability needed for light homogeneity.
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 significantly reduces light losses and reflections, achieving high homogeneity and decoupling efficiency while simplifying and cost-reducing the manufacturing process by avoiding phase boundaries and material incompatibilities, ensuring consistent light distribution and color stability along the LED module.
Implementation Method 1
a light-scattering matrix material can be introduced into the housing, by whose light mixing and stray effect a homogeneous one Emptying the light is made possible
Implementation Method 2
At least one first base layer of a hardenable material is filled in a unused state by the opening into the housing and furthermore, a spreader of a stray layer is filled in a non-cured state by the opening into the housing. According to a first aspect of the invention, the scattering layer is filled onto the first base layer, wherein the first base layer is not cured when filling the spreading layer, and after filling the stray layer, the at least one first base layer and the stray layer are cured.
Data Source
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AI summary
The present invention relates to a method for producing an LED module and an LED module, by means of which a high out-coupling efficiency and homogeneity of the emitted light can be provided. In the method according to a first aspect of the invention, a housing (26) is initially provided, which has a base side (28) on which a circuit board (36) with at least one LED (32) is arranged. In addition, at least one first base layer (22) made of a curable material is poured in a non-cured state into the housing (26). A scattering layer (24) made of a curable material is also poured into the housing in a non-cured state. The scattering layer (24) is poured onto the first base layer (22), the first base layer (22) not being cured when the scattering layer (24) is poured in, and after the scattering layer (24) is poured in, the at least one first base layer (22) and the scattering layer (24) are cured.