Reflective Suspension for Light Emitting Device
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Solution Overview
Problem
Conventional light emitting devices face challenges in achieving improved light output, efficient collimation, and material usage, with issues such as light absorption by substrates and potential for uneven powder dispersion leading to reduced reflectivity and artifacts in applications like automotive headlamps.
Innovation Solution
A light emitting device featuring a reflective optic housing with a suspension of reflective material filling the space between the housing and the light emitter, which reflects non-desirable light emissions back into the emitter, enhancing collimation and light output, while also providing mechanical protection and reducing material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If dry powder is used to create a reflective surface, then reflectivity is improved, but the device complexity increases due to the need for binding means and covering plates
Solution Approach 1:
The patent extracts the binding means (covering plates, holes) from the system by using a suspension that self-adheres to the substrate, eliminating the need for additional binding components while maintaining the reflective surface functionality
Solution Approach 2:
The patent changes the physical state of the reflective material from dry powder to a suspension form, which allows the material to be applied and fixed without additional binding means, thus reducing device complexity while maintaining reflectivity
2Illumination intensity
If a thick powder layer is used to obtain high reflectivity, then reflectivity is improved, but the loss of substance increases due to material consumption
Solution Approach 1:
The patent changes the application form from thick dry powder layer to a controlled suspension coating, which achieves high reflectivity with minimal material consumption by forming a uniform thin layer that adheres to the substrate
Solution Approach 2:
The suspension formulation allows for a thin, efficient coating that uses minimal reflective material to achieve the desired optical performance, reducing overall material consumption
3Illumination intensity
If dry powder is used for light reflection, then light output is improved, but the manufacturing precision decreases due to uneven dispersion
Solution Approach 1:
The patent transforms the reflective material from dry powder to a suspension state, which enables uniform dispersion through fluid dynamics and capillary action, eliminating the clustering and uneven distribution problems associated with dry powder application
Solution Approach 2:
The suspension is applied as a fluid that distributes evenly through the optical housing, using fluid flow characteristics to achieve uniform coverage and consistent reflectivity across the substrate surface
4Device complexity
If no barrier is used between light emitters, then device complexity is reduced, but the loss of information increases due to cross-talk between emitters
Solution Approach 1:
The suspension serves multiple functions simultaneously: it provides the reflective surface for light redirection, acts as a barrier to prevent cross-talk between adjacent emitters, and adheres to the substrate without requiring additional binding means, thus maintaining low device complexity while preventing information loss
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 increases light output, reduces material usage, and minimizes cross-talk between light emitters, while improving heat conduction and environmental sealing, resulting in enhanced optical efficiency and mechanical robustness.
Implementation Method 1
One effect of the suspension is to reflect light emitted in non-desirable directions, such as to the sides, which otherwise would be partly absorbed by the substrate and not collimated or mixed properly, with an efficiency loss as a result. Hence, the suspension reflects light emitted from the light emitter.
Implementation Method 2
The suspension of the reflective material may also improve the heat conduction between the light emitter and/or die and/or Lumiramic and/or TFFC and the substrate.
Data Source
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AI summary
The present invention relates to a light emitting device (100) comprising at least one light emitter (101), a substrate (102) and a reflective optic housing (103,108), the space between the reflective optic housing (103,108) and the one or more light emitters (101) being filled at least partly by a suspension of a reflective material (104), in order to increase the light output from the light emitter(s) (101).