LED Submount and Silicone Dam Structure for Wide Viewing Angles
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Solution Overview
Problem
Existing LED components have inadequate viewing angles, particularly in surface mount design (SMD) components, which are limited to about 115°, making them unsuitable for wide-angle lighting applications like light bulbs, where uniform light extraction is desired.
Innovation Solution
The development of LED components featuring a submount with at least one LED chip and a non-reflective, light-permeable structure or dam made of silicone with fillers or binders, providing a viewing angle of 120° or more, enhancing light extraction and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If existing SMD LED components are used, then manufacturing is simple and cost-effective, but the viewing angle is limited to about 115° which is inadequate for wide-angle lighting applications
Solution Approach 1:
The LED component is divided into distinct functional segments: the LED chip mounted on the submount, and the separate non-reflective dam structure surrounding the chip. This segmentation allows independent optimization of each component - the submount provides mechanical support and electrical connection, while the dam structure specifically addresses the viewing angle limitation by redirecting lateral light emission, thereby improving illumination distribution without complicating the overall device architecture
Solution Approach 2:
The non-reflective dam acts as an intermediary element between the LED chip and the surrounding environment. It mediates the light emission by capturing lateral light rays that would otherwise be lost and redirecting them toward the viewing axis, effectively converting unusable lateral emission into useful forward light. This intermediary structure resolves the contradiction by adding a relatively simple component that significantly enhances viewing angle performance
2Stability of the object's composition
If a non-reflective dam structure is added to increase viewing angle, then light extraction uniformity improves, but manufacturing complexity increases
Solution Approach 1:
The dam structure's optical parameters are specifically optimized to achieve uniform light extraction. By controlling the dam's height, thickness, and distance from the LED chip, the design transforms the non-uniform lateral light emission into uniform omnidirectional radiation. The non-reflective material parameter is selected to maximize light absorption and redirection efficiency, thereby achieving composition stability in terms of uniform light output while maintaining manufacturability through well-defined geometric parameters
Solution Approach 2:
The non-reflective dam is constructed using composite materials that combine non-reflective properties with structural integrity. This composite approach allows the dam to simultaneously perform multiple functions: mechanically supporting the LED chip, optically redirecting light, and maintaining the desired geometric shape during manufacturing. The composite material solution enables uniform light extraction without significantly increasing manufacturing complexity, as the same material can be applied through standard dispensing or molding processes
3Adaptability or versatility
If LED components are designed for wider viewing angles, then suitability for light bulb applications increases, but production cost may increase
Solution Approach 1:
The non-reflective dam structure serves multiple functions simultaneously: it acts as a mechanical support element, an optical redirector for enhancing viewing angle, and a structural component that defines the component's overall shape. This multi-functionality allows the same structural element to achieve wide viewing angle performance suitable for light bulb applications without requiring additional separate components, thereby avoiding increased raw material consumption and production costs while maintaining application versatility
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 achieves improved manufacturability and light extraction for various lighting applications, including light bulbs, by increasing the viewing angle beyond 115°, making LED components more suitable for wide-angle lighting needs.
Implementation Method 1
a non-reflective, light permeable structure or dam disposed on the first surface of the submount about (around) the at least one LED chip for providing a component having an improved viewing angle
Implementation Method 2
The non-reflective structure can comprise a silicone dam having one or more fillers or binders
Data Source
AI summary
Light emitting diode (LED) components and related methods are disclosed. LED components include a submount, at least one LED chip on a first surface of the submount, and a light permeable structure or dam. The light permeable dam can provide a component having a viewing angle that is greater than 115°. A method of providing an LED component includes providing a non-metallic submount, attaching at least one LED chip to a first surface of the submount, and dispensing a light permeable dam over the first surface of the submount about the at least one LED chip thereby providing a component having a viewing angle that is greater than 115°.