Near Field Mixing LED Component with Diffuser
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Solution Overview
Problem
Conventional LED packages face challenges in achieving high light flux levels above 1000 lumens in a compact form factor due to limited input power and increased 'dead space' between discrete LED packages, which hinders efficient light mixing and beam shaping.
Innovation Solution
The implementation of near-field light mixing using a diffuser material or structure in close proximity to discrete LED sources, allowing for a low-profile LED component that appears as a single color source when viewed directly, while maintaining efficient light mixing and beam shaping capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple discrete LED packages are mounted to achieve high light flux levels, then the total luminous output increases, but the 'dead space' between packages increases which hinders efficient light mixing and beam shaping
Solution Approach 1:
The patent merges multiple discrete LED packages into a single integrated LED component structure. The LED array is mounted on a common submount with integrated electrical connections, and the entire assembly is covered by a single lens with a diffuser layer. This integration eliminates the dead space between separate packages while maintaining high light flux output through the combined emission of multiple LED chips arranged in series/parallel circuits.
2Volume of moving object
If discrete LED packages are used individually, then each package has a compact form factor, but achieving high light flux levels requires multiple packages which creates excessive dead space
Solution Approach 1:
The patent transitions from mounting LEDs in a planar array to a three-dimensional configuration where LED chips are stacked vertically on the submount. This vertical stacking approach increases the light flux output within a compact footprint by utilizing the vertical dimension, thereby achieving high luminous output without proportionally increasing the horizontal dead space between packages.
3Illumination intensity
If far field mixing is used to combine light from discrete sources, then the individual sources can be perceived when viewed directly, but mechanically obscuring them results in lower efficiency due to light loss
Solution Approach 1:
The patent introduces a diffuser layer as an intermediary element within the lens structure, positioned in close proximity to the LED chips. This near-field diffuser mixes the light from discrete LED sources before it travels far, creating a uniform perceived light source without requiring mechanical obscuration. The diffuser achieves effective light mixing while minimizing energy loss by allowing light to pass through rather than being blocked by shields.
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 approach enables the creation of compact LED lamps that deliver high light flux levels with improved light mixing and beam control, reducing 'dead space' and enhancing the visual appeal and efficiency of LED lighting solutions.
Implementation Method 1
whose emissions are mixed in the near field by providing a scattering/diffuser material or structure ('diffuser') in close proximity to the light sources
Data Source
Figure 1a~2
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Figure 7a~7d
AI summary
A light emitting diode (LED) component comprising a submount with an array of LED chips and a lens over the array of LED chips. A diffuser is arranged so that at least some light from the LEDs passes through the diffuser to mix the LED light in the near field. The light passing through the diffuser appears as a mixture of LED chip light when directly viewed. A lighting device is also disclosed comprising an LED component comprising an array of LED chips and a near field diffuser to mix at least some of the light from the LED chips in the near field. A remote reflector is included to reflect at least some the light from the LED component so that is emits from the lighting device in the desired direction.