LED Package Inclined Reflectors for Beam Angle Control

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Solution Overview

Problem

Existing LED packages with wide beam angles require separate lenses to control light direction, increasing manufacturing costs and potentially reducing reliability due to moisture ingress and light absorption issues.

Innovation Solution

A light-emitting diode package design with inclined package main bodies around the LED chips, where the second inclined side is closer to the chips than the first, reflecting light beams to control the beam angle without a separate lens, and an envelope material spaced at least 0.05 mm from the second inclined side to prevent luminance unevenness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a separate lens is added to control beam angle, then beam angle control is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvebeam angle controlVSAvoidpackage structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent removes the separate lens component from the LED package structure. Instead of adding a lens to control beam angle, the invention extracts this function entirely by using the package housing itself as the light-directing element, thereby simplifying the overall device structure while maintaining beam angle control capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The package housing is designed to serve multiple functions simultaneously: it provides mechanical protection for the LED chips, structural support for the package, and optical direction control for the emitted light. This multi-functionality eliminates the need for separate dedicated components for each function, reducing device complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If a lens is added to control beam angle, then beam angle control is improved, but manufacturing cost increases

Engineering Contradiction:

Improvebeam angle controlVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent combines the beam angle control function with the existing package housing structure. By integrating the light-directing function into the housing that already serves protective and structural roles, the invention eliminates the need for separate lens components and their associated manufacturing processes, thereby reducing overall manufacturing cost

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses the package housing material itself to perform optical direction control rather than requiring expensive precision lens materials. The housing is molded with specific geometric features that provide beam angle control, utilizing readily available moldable materials instead of costly optical components

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If reflection side is added to reduce beam angle, then beam angle control is improved, but light absorption increases and manufacturing cost increases

Engineering Contradiction:

Improvebeam angle controlVSAvoidlight absorption

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The patent employs curved or inclined surface geometries on the package housing to redirect light beams. These curved surfaces naturally reflect and redirect light at desired angles without requiring high-reflectivity coating materials, thereby minimizing light absorption losses while achieving beam angle control

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The invention controls beam angle by changing the geometric parameters of the package housing surfaces (such as inclination angles and surface curvatures) rather than relying on material reflectivity properties. This approach achieves optical control through geometry alone, avoiding the need for reflective coatings that would increase manufacturing cost and potential light absorption

Inventive Principle:

Principle #35Parameter changes

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 design reduces manufacturing costs, increases luminance by controlling optical loss, and enhances reliability by minimizing power consumption and photo pollution while maintaining beam angle control.

Implementation Method 1

reflecting light beams to control the beam angle

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS11848196B2Light-emitting diode package having controlled beam angle and light-emitting device using same

Publication Date: 2023.12.19 JIN JEA UN

AI summary

A light-emitting diode package having a controlled beam angle is proposed. The diode package can include at least one first lead frame; at least one second lead frame formed to correspond to and be spaced apart from the at least one first lead frame; light-emitting diode chips mounted on the at least one first lead frame; a first package main body which is fixed on the partial surfaces of the at least one first lead frame and the at least one second lead frame and formed so as to have a first inclined side at a portion of the circumference around the light-emitting diode chips; and a second package main body formed so as to have a second inclined side at the remaining portion of the circumference around the light-emitting diode chips other than the portion.