Notched Concave Reflector for Compact High-Intensity LED Module
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Solution Overview
Problem
Existing light-emitting modules for image projection systems face challenges in achieving high intensity, efficiency, and compact size due to large size and inefficient light distribution, and existing solutions like dichroic prisms increase cost and size, while parallel arrangements of modules lead to upsizing and inefficient illumination.
Innovation Solution
A light-emitting module with a single reflector having multiple concave reflection surfaces arranged in rotational symmetry, where each surface is partially notched at the boundary, allowing for efficient light emission and heat dissipation, and using LEDs emitting light towards these surfaces to achieve high intensity and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple light-emitting modules are arranged in parallel to achieve higher intensity, then light intensity increases, but the overall size increases and illumination efficiency decreases
Solution Approach 1:
The patent combines multiple concave reflection surfaces into a single integrated reflector structure, allowing multiple LED chips to be arranged in a compact configuration. This merging approach achieves high light intensity through multiple LEDs while maintaining a compact overall size, resolving the contradiction between intensity and size.
Solution Approach 2:
The patent uses a three-dimensional concave reflection surface structure that efficiently directs light in specific directions. By utilizing spatial dimensionality and angular distribution, the design achieves high illumination intensity without requiring a larger physical footprint, thus resolving the size-intensity tradeoff.
2Illumination intensity
If multiple LED chips are used on one reflection surface to achieve higher intensity, then light intensity increases, but the angle of light distribution becomes very large and light distribution characteristics deteriorate
Solution Approach 1:
The reflector is segmented into multiple distinct concave reflection surfaces, each optimized to work with specific LED chips. This segmentation allows each LED-chip-reflector combination to maintain optimal light distribution characteristics while collectively achieving high intensity through the combined output of multiple segments.
Solution Approach 2:
Each concave reflection surface is locally optimized with specific geometric parameters to control light distribution angles. The local quality of each reflection surface is tailored to achieve uniform light distribution, preventing excessive angular spread while maintaining high intensity through the combined effect of multiple locally-optimized surfaces.
3Adaptability or versatility
If a dichroic prism is used to synthesize light of respective colors, then full color is achieved, but cost increases and space requirements increase
Solution Approach 1:
The patent uses a single reflector structure that serves multiple functions: it reflects light from multiple LED chips, controls light distribution angles, and enables full-color output through the combined emission of RGB LEDs. This multi-functional design eliminates the need for separate dichroic prisms, reducing both cost and device complexity while maintaining full color capability.
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 enables a high-intensity, efficient, and compact light-emitting module that prevents light ununiformity and heat buildup, allowing for a small-size, low-cost image projection apparatus with improved light distribution and cooling efficiency.
Implementation Method 1
a single reflector having a plurality of concave reflection surfaces... each of the light emitters emitting light toward the concave reflection surface
Implementation Method 2
an electrode lead connected to the LED chip also functions as a heat sink, thus permitting a certain degree of improvement in the efficiency
Data Source
AI summary
A light-emitting module has: a single reflector having a plurality of concave reflection surfaces; and light emitters in a same number as a number of the concave reflection surfaces. Each of the concave reflection surface has an outer shape partially notched at a boundary thereof with the adjacent concave reflection surface. Each of the light emitters emits light toward the concave reflection surface.