LED Package Reflector Cavity Angled Walls
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Solution Overview
Problem
Current LED packages face challenges in increasing view angle, maintaining low operating temperature, and reducing size while addressing issues of incomplete molding, voids, and heat dissipation, which affect brightness and color fidelity, especially in indoor and outdoor displays.
Innovation Solution
The development of LED packages with a reflector cavity featuring angled wall portions and a thermally conductive casing made from materials like polyphthalamide (PPA) that enhance reflectivity and heat dissipation, allowing for a thinner profile and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If cavity angles are increased to assist in exceeding brightness specifications, then brightness is improved, but package material incompletely molds about package components leading to gaps, voids, and low adhesion
Solution Approach 1:
The cavity is divided into multiple sections with different angle characteristics. The reflector cavity includes a first cavity portion with a first angle and a second cavity portion with a second angle, allowing each section to be optimized independently for both light extraction and molding completeness
Solution Approach 2:
Different regions of the cavity are assigned different geometric properties. The first cavity portion has optimized angles for light extraction while the second cavity portion has angles optimized for complete molding, creating local quality variations that resolve the global contradiction
2Volume of moving object
If LED size is reduced to achieve smaller packages, then package size is reduced, but heat dissipation becomes more challenging
Solution Approach 1:
The solution moves from two-dimensional planar reflection to three-dimensional angled cavity structures. The angled wall portions create volumetric light paths that increase surface area for light extraction without increasing the overall package footprint, effectively adding a dimensional approach to heat management
Solution Approach 2:
The reflector cavity with angled walls acts as an intermediary structure between the LED chip and the external environment. It provides an intermediate light path that increases effective surface area for light extraction and heat dissipation without requiring larger package dimensions
3Adaptability or versatility
If view angle is increased to improve viewing characteristics, then color fidelity varies across viewing angles
Solution Approach 1:
The cavity employs asymmetric angled wall portions with different angles for different cavity portions. This asymmetric geometry is specifically designed to control light extraction patterns across different viewing angles, maintaining color fidelity consistency while expanding the usable viewing angle range
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 achieves increased brightness, improved color fidelity across a wide range of viewing angles, reduced heat dissipation challenges, and a more reliable LED package with enhanced thermal and optical properties, suitable for both indoor and outdoor applications.
Implementation Method 1
reflector cavity with angled wall portions for housing LED devices and reflecting light therefrom
Implementation Method 2
thermally conductive casing made from materials like polyphthalamide (PPA) that enhance reflectivity and heat dissipation
Data Source
AI summary
Packages, systems, and devices for light emitting diodes (LEDs) and related methods are provided. The packages can include a lead frame with an electrically conductive chip carrier comprising an upper surface. An LED can be placed on the upper surface of the electrically conductive chip carrier. A casing can be disposed on the lead frame covering at least a portion of the lead frame. A reflector cavity can be in the casing surrounding the LED. The reflector cavity can have angled side wall portions and angled end wall portions with an angle at which the side wall portions are angled that is different from an angle at which the end wall portions are angled.