Reflector Housing for LED Optical Devices
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Solution Overview
Problem
Large display panels face issues with moisture absorption in plastic housings for LED light emitting elements, leading to failures, and the use of plastic plates to hide components complicates housing design, either increasing mass or making housings prone to cracking.
Innovation Solution
The optical device features a reflector housing with a top cavity for LED dies and a bottom cavity surrounded by a peripheral wall, reducing mass and moisture absorption while maintaining strength, and can be coated with a potting material to protect the LEDs and avoid obscuration by surrounding plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing mass is increased to improve strength, then mechanical strength is improved, but moisture absorption increases
Solution Approach 1:
The patent uses a two-material construction combining metal (aluminum or steel) and plastic. The metal base provides structural strength and rigidity while the plastic coating provides moisture protection. This composite approach allows the housing to achieve both mechanical strength and moisture resistance without increasing overall mass, directly resolving the contradiction between strength and moisture absorption.
2Length of moving object
If the housing height is increased to avoid obscuration by plastic plates, then light output visibility is improved, but housing mass increases
Solution Approach 1:
The metal-plastic composite construction enables the housing to achieve greater height without proportionally increasing mass. The metal framework provides structural support at minimal weight, allowing the housing to extend taller to clear plastic plates while the plastic coating maintains moisture protection. This resolves the contradiction between height and mass that plagues traditional all-plastic housings.
3Object-affected harmful factors
If the housing is made lighter to reduce moisture absorption, then moisture absorption decreases, but mechanical strength decreases
Solution Approach 1:
The patent's composite construction assigns different functions to different materials: the metal base provides mechanical strength and rigidity, while the plastic coating provides moisture barrier protection. This division of labor allows the housing to be lighter than solid metal constructions while maintaining both strength and moisture resistance, directly resolving the contradiction between weight and strength.
4Weight of moving object
If the housing is made flimsy to reduce mass, then housing mass decreases, but susceptibility to cracking increases
Solution Approach 1:
The metal-plastic composite construction provides both light weight and high reliability. The metal framework offers exceptional strength-to-weight ratio and resistance to cracking, while the plastic coating adds flexibility and moisture protection. This composite approach allows the housing to be lightweight yet highly resistant to cracking and physical failures, resolving the contradiction between mass and reliability.
Data Source
AI summary
An exemplary embodiment of an optical device may include a lead frame with a plurality of leads and a reflector housing formed around the lead frame. The reflector housing includes a first end face and a second end face and a peripheral sidewall extending between the first end face and the second end face. The reflector housing includes a first pocket with a pocket opening in the first end face and a second pocket with a pocket opening in the second end face. At least one LED die is mounted in the first pocket of the reflector housing, and a light transmitting encapsulant is disposed in the first pocket and encapsulating the at least one LED die.