LED Optical Element with Bottom Reflector for Mount Isolation
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Solution Overview
Problem
Current lighting devices face challenges in minimizing light reflection from the mount onto which light-emitting diodes (LEDs) are attached, leading to reduced light extraction efficiency, particularly when using mounts with low reflectivity.
Innovation Solution
A reflector is disposed on the bottom surface of an optical element optically coupled to the LED, minimizing light incidence onto the mount and allowing the use of mounts with low reflectivity without impacting light extraction, while a wavelength converting material is used to alter the light spectrum, and the optical element is molded over the LED to provide mechanical connection without additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mount with low reflectivity is used to attach the LED, then the mount can be made with simpler or lower-cost materials, but light extraction efficiency is reduced due to increased light reflection onto the mount
Solution Approach 1:
A reflector is introduced as an intermediary component between the optical element and the mount. This reflector redirects light that would otherwise reflect onto the mount back toward the optical element, allowing the use of low-reflectivity mount materials without sacrificing light extraction efficiency. The reflector acts as a mediator that decouples the mount's optical properties from the overall system performance.
2Loss of energy
If a reflector is added to the bottom of the optical element, then light extraction efficiency is improved, but device complexity increases
Solution Approach 1:
The reflector is integrated with the optical element to form a single combined component. Rather than being a separate attached element, the reflector is molded as part of the optical element structure, reducing assembly steps and simplifying the overall device while maintaining the light extraction efficiency benefit.
Solution Approach 2:
The optical element is designed to serve multiple functions: it provides the primary optical function while also incorporating the reflector function in its bottom portion. This multi-functionality reduces the need for separate components and simplifies the overall device structure.
3Device complexity
If the optical element is molded directly over the LED, then mechanical connection is provided without additional support, but manufacturing precision requirements increase
Solution Approach 1:
The LED is pre-positioned and secured to the mount before the optical element is molded over it. This preliminary positioning ensures correct alignment and spacing, allowing the subsequent molding process to proceed with standard precision requirements rather than requiring high-precision alignment during molding.
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 enhances light extraction efficiency by reducing reflections and allows for the use of low-reflectivity mounts, while also enabling tailored light spectra through wavelength conversion, improving overall lighting performance.
Implementation Method 1
A reflector is disposed on the bottom surface of an optical element optically coupled to the LED, minimizing light incidence onto the mount
Implementation Method 2
a wavelength converting material is used to alter the light spectrum
Data Source
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AI summary
A structure according to embodiments of the invention includes a semiconductor light emitting device and an optical element disposed over the semiconductor light emitting device. The semiconductor light emitting device is disposed in a recess in the optical element. A reflector is disposed on a bottom surface of the optical element. A method according to embodiments of the invention includes disposing a semiconductor light emitting device on a substrate and forming a reflector adjacent the semiconductor light emitting device. An optical element is formed over the semiconductor light emitting device. The semiconductor light emitting device is removed from the substrate.