Reflective Plate Wavelength Conversion for LED Lighting
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Solution Overview
Problem
Conventional lighting devices using remote phosphor techniques for white light LEDs face increased manufacturing costs due to excessive phosphor usage and potential damage from heat generated by LED chips, making it costly and inefficient to maintain color temperature.
Innovation Solution
A lighting device design featuring a light bar with reflective covers and a reflective plate spaced apart, where the wavelength conversion layer is positioned on the reflective plate, reducing phosphor usage and avoiding direct heat contact, allowing for efficient light conversion and easy color temperature adjustment by replacing the wavelength conversion layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphors are coated on a diffusion sheet using remote phosphor technique, then phosphors are protected from heat damage, but phosphor usage increases substantially leading to higher manufacturing costs
Solution Approach 1:
The patent introduces a reflective plate positioned at a specific distance from the light output side, creating a spatial dimension for light reflection. This allows the wavelength conversion layer to be positioned on the reflective plate rather than on a diffusion sheet, reducing the area requiring phosphor coating while maintaining protection from heat damage through the spaced configuration.
Solution Approach 2:
The reflective plate is positioned to receive light from a specific area of the light output side, creating a localized region for wavelength conversion. This allows phosphors to be applied only where needed on the reflective plate surface, rather than coating an entire diffusion sheet, thereby reducing overall phosphor usage while maintaining effective light conversion in the critical region.
2Ease of manufacture
If phosphors are mixed with sealant of LED, then manufacturing process is simplified, but phosphors are affected by heat generated from LED chip
Solution Approach 1:
The patent extracts the wavelength conversion function from the LED sealant mixture and relocates it to a separate wavelength conversion layer on the reflective plate. This separation removes the phosphors from the high-heat environment near the LED chip while maintaining the wavelength conversion capability, protecting the phosphors from heat damage.
Solution Approach 2:
The reflective plate serves as an intermediary component between the LED light source and the wavelength conversion layer. By positioning the wavelength conversion layer on the reflective plate at a spaced distance, the system mediates the interaction between light and phosphors, allowing heat management while maintaining optical functionality.
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 design reduces phosphor usage, prolongs the service life of wavelength conversion materials, and simplifies color temperature changes by allowing for easy replacement of the wavelength conversion layer, thereby lowering manufacturing costs and enhancing maintenance flexibility.
Implementation Method 1
a portion of the first wavelength light is converted by the wavelength conversion layer of the reflective plate into a second wavelength light
Implementation Method 2
the reflective plate has a wavelength conversion layer positioned on the reflective surface thereof. The light bar emits a first wavelength light, and a portion of the first wavelength light is converted by the wavelength conversion layer of the reflective plate into a second wavelength light which is then reflected by the reflective plate to the two reflective covers
Data Source
AI summary
A lighting device includes a light bar, two reflective covers and a reflective plate. The two reflective covers respectively connected to two opposite long sides of the light bar. The reflective plate is positioned at the light output side of the light bar. The reflective surface of the reflective plate faces the light output side of the light bar. The reflective plate has a wavelength conversion layer positioned on the reflective surface thereof. The light bar emits a first wavelength light, and a portion of the first wavelength light is converted by the wavelength conversion layer into a second wavelength light which is reflected by the reflective plate to the two reflective covers, while the remaining non-converted first wavelength light is reflected by the reflective plate to the two reflective covers and mixed with the second wavelength lights to give a light with a predetermined spectrum.