Light Engine With High-Reflective Chamber For Brightness

The patent combines multiple LED dies within a single fixture to create a light engine that produces both high luminous flux and high brightness. By integrating several LED dies in close proximity and using optical elements to collect and redirect their light, the system achieves the luminous flux of multiple sources while maintaining the brightness concentration needed for applications like automotive headlights.

The patent employs a nested structure where multiple LED dies are positioned within a compact fixture, and optical elements are nested around and between the LEDs. This allows maximum utilization of space, enabling multiple light sources to be packed closely together without requiring excessive spacing, thereby maintaining high brightness while achieving cumulative luminous flux.

The patent converts the typically harmful reflective losses into beneficial light redirection. By strategically positioning reflective surfaces within the fixture, light that would otherwise be lost through reflections is redirected toward the desired output direction. This approach maintains good light direction control while significantly reducing net light loss compared to traditional secondary optics.

The patent extracts and eliminates the need for complex secondary optics by using a simplified optical design. Instead of relying on additional lenses and reflectors that cause multiple reflections and light loss, the invention uses a direct optical path with minimal intervention, achieving adequate light direction control through the geometric arrangement of LED dies and simple optical elements.

The patent designs the fixture components to serve multiple functions simultaneously. The housing structure provides both mechanical support and optical reflection functions; the optical elements perform both light extraction and direction control; the heat sink serves both thermal management and structural support. This multi-functionality reduces the number of separate components needed, simplifying the overall device while maintaining light transport capability.

The patent merges multiple functions into fewer components. Instead of having separate elements for mounting, heat dissipation, and optical reflection, these functions are combined into integrated fixture structures. This reduction in component count directly lowers production cost and device complexity while preserving the necessary light transport capabilities through careful optical design of the integrated structures.