Polymer Blend Light Diffusion Element for LED Fixtures
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Solution Overview
Problem
Conventional light diffusion elements for LEDs face challenges in evenly dispersing inorganic particles within organic polymers, leading to increased production complexity and cost, and fail to provide evenly distributed light, potentially harming users with harsh focused brightness.
Innovation Solution
A light diffusion element composed of a blend of two polymers with different crystal diameters, where the first polymer has a larger crystal diameter than the second, allowing for excellent light diffusion properties without the need for additional light diffusion agents or particles, and can be molded using existing thermoplastic methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If inorganic particles are added to polymers to create light diffusion elements, then light diffusion capability is improved, but manufacturing complexity and cost increase due to difficulty in even dispersion
Solution Approach 1:
The invention extracts and eliminates the inorganic particles from the light diffusion element composition, using only organic polymers with different crystal diameters to achieve light diffusion. This removes the dispersion problems and surface modification requirements associated with inorganic particles while maintaining the light diffusion function.
Solution Approach 2:
The invention changes the key parameter from particle size distribution of inorganic additives to crystal diameter distribution of organic polymers. By controlling the crystal diameter of polymers rather than adding inorganic particles, the system achieves light diffusion through a parameter that is inherently controllable through standard polymer processing.
2Illumination intensity
If wave- or lens-shaped micro structures are created on polymer surface to diffuse light, then light distribution evenness is improved, but production complexity and cost increase
Solution Approach 1:
The invention changes the approach from creating geometric micro-structures on the surface to controlling the internal crystal diameter parameter of the polymer material itself. This parameter change allows light diffusion to be achieved through material selection rather than complex surface structuring.
Solution Approach 2:
The invention uses standard thermoplastic polymers that can be molded using existing processes, replacing the need for expensive and complex micro-structure fabrication processes. The solution leverages readily available polymer materials and conventional molding techniques.
3Power
If LED brightness is increased to enhance surrounding illumination, then lighting efficiency is improved, but harsh focused brightness is generated that can damage user eyes
Solution Approach 1:
The invention applies local quality by using polymers with different crystal diameters in specific proportions to create localized light diffusion properties. The blend ratio and crystal diameter distribution are optimized to achieve the desired light distribution pattern that eliminates harsh focused brightness while maintaining overall illumination efficiency.
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 polymer blend achieves higher light diffusion rates and transmission than individual polymers, reducing production costs and ensuring even light distribution, thus mitigating the harshness of focused LED brightness.
Implementation Method 1
the light diffusion element comprises a first polymer, a second polymer, or a blend of the first polymer and the second polymer. The first polymer has a larger crystal diameter than that of the second polymer
Data Source
AI summary
Disclosed is a light-emitting device, including an LED light source and a light diffusion element. The light diffusion element, covering at least a part of the LED light source, is composed of a first polymer, a second polymer, or a blend of them. The first polymer has a larger crystal diameter than that of the second polymer. The first polymer is made of polypropylene or ethylene-propylene copolymer. The second polymer is made of polyethylene, polypropylene, or ethylene-propylene copolymer. A blend of certain ratios of the first and second polymer gives rise of an excellent material that has improved light diffusion. This material can be widely adopted to current light fixtures for its evenly distributed lighting and great brightness.