LED Light Source with Multi-Lens Pattern Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current LED light bulbs have limited illumination coverage, leading to user misconceptions about their effectiveness, and existing solutions to increase coverage, such as bonding LED chips onto inclined heat sink surfaces, are difficult to implement and not suitable for mass production.
Innovation Solution
An LED light source design featuring a carrier with multiple LED chips and sets of lenses, where each lens converts the light pattern into a distinct distribution, enhancing illumination coverage by combining different lighting patterns to achieve greater than 180° coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LED chips are bonded onto inclined surfaces of a heat sink to increase illumination coverage, then illumination coverage is improved (greater than 290°), but manufacturing difficulty increases and mass production becomes difficult
Solution Approach 1:
The patent divides the illumination function into multiple independent LED chips, each with its own lens assembly. Instead of bonding chips to inclined heat sink surfaces, each chip is mounted on a flat carrier and equipped with a separate lens that directs light in specific directions. This segmentation allows for easier manufacturing while achieving wide illumination coverage through the combined effect of multiple directed light sources.
Solution Approach 2:
The patent introduces lenses as intermediary components between the LED chips and the surrounding environment. These lenses act as mediators that shape and direct the light output from each chip, enabling precise control over illumination patterns. The lenses replace the need for complex inclined bonding structures by providing a simpler, more manufacturable approach to achieving wide illumination coverage.
2Illumination intensity
If LED chips are bonded onto two opposite surfaces of the heat sink to increase illumination coverage, then illumination coverage is improved (greater than 290°), but device complexity increases
Solution Approach 1:
The patent segments the illumination system into multiple independent units, each consisting of an LED chip and its own lens assembly mounted on a flat carrier. This modular segmentation simplifies the overall design compared to bonding chips to opposite surfaces of a heat sink, as each unit can be manufactured and assembled independently before being integrated into the final device.
Solution Approach 2:
The patent transitions from a vertical arrangement (bonding chips to opposite surfaces of a heat sink) to a horizontal arrangement (mounting chips on a flat carrier with lenses positioned above them). This dimensional change simplifies the manufacturing process and reduces design complexity while maintaining the ability to achieve wide illumination coverage through the combined output of multiple chips.
3Ease of manufacture
If a single lens is used to encapsulate LED chips, then manufacturing is simplified, but illumination coverage remains limited (about 120°)
Solution Approach 1:
The patent merges multiple LED chip-lens units into a single integrated assembly on a flat carrier. Each unit maintains manufacturing simplicity with its own encapsulating lens, while the combined output of multiple units achieves wide illumination coverage. The merging approach allows the system to benefit from both manufacturing simplicity and enhanced illumination performance simultaneously.
Solution Approach 2:
The patent segments the illumination function across multiple independent LED chip-lens units, each maintaining simple manufacturing processes. The individual segments are then integrated into a unified system where their combined effect achieves wide illumination coverage. This segmentation strategy preserves manufacturing simplicity while overcoming the limitations of a single lens.
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 solution provides LED light sources with large illumination coverage, making them suitable for various applications by creating mixed lighting patterns that compensate for each other, thereby overcoming the limitations of existing LED light bulbs.
Implementation Method 1
The first lens encapsulates one of the LED chips and a lighting pattern provided from the LED chip encapsulated by the first lens is converted into a first lighting pattern
Data Source
AI summary
An LED light source includes a carrier, a plurality of LED chips and at least one set of lenses. The carrier has a mounting surface and the LED chips are mounted on the mounting surface. The set of lenses disposed on the carrier includes a first lens and a second lens, and the first lens encapsulates one of the LED chips and a lighting pattern provided from the LED chip encapsulated by the first lens is converted into a first lighting pattern. The second lens encapsulates one of the LED chips and a lighting pattern provided from the LED chip encapsulated by the second lens is converted into a second lighting pattern. The second lighting pattern is different from or compensates the first lighting pattern.