Segmented Reflective Ring and Upper Reflector for LED Light Collimation
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Solution Overview
Problem
Existing LED illumination systems face challenges in achieving precise light emission patterns for applications like projection displays and automotive headlights, as simple optical techniques are inadequate for directing light efficiently within narrow specifications.
Innovation Solution
The use of precision collection optics comprising a small reflective ring with reflective sidewalls surrounding LEDs and a separate upper reflector, where the reflective ring acts as a lateral positioning guide for both components, allowing for high-precision manufacturing and assembly, reducing costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple optical techniques (lens or reflective cup) are used to redirect LED light, then device complexity is reduced, but light emission pattern precision deteriorates
Solution Approach 1:
The collection optics is divided into multiple discrete reflective pieces (first piece, second piece, third piece) rather than using a single simple reflector. Each piece is positioned at specific angles to collectively achieve precise light redirection, allowing the system to maintain low complexity while achieving high emission pattern precision through modular arrangement.
2Manufacturing precision
If precision collection optics with multiple pieces are used to achieve desired emission pattern, then light emission precision is improved, but device complexity increases
Solution Approach 1:
The optics is segmented into multiple reflective pieces that can be independently manufactured and positioned. This segmentation allows each component to be optimized for its specific function while collectively achieving the overall precise emission pattern, balancing complexity and precision.
Solution Approach 2:
The reflective pieces are arranged in three-dimensional space around the LED source at different angular positions and distances. By utilizing spatial arrangement in multiple dimensions, the system achieves precise light control without requiring each individual component to be overly complex.
3Manufacturing precision
If high precision manufacturing and positioning is used for collection optics, then light emission precision is improved, but manufacturing time and cost increase
Solution Approach 1:
Dividing the optics into separate pieces allows for standardized manufacturing processes for each component. This enables parallel production and simplifies quality control, improving manufacturing efficiency while maintaining the precision needed for accurate light emission patterns.
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 efficient collimation of light and reduces manufacturing and assembly time and costs by allowing for relaxed tolerances in the upper reflector's placement, while maintaining precise light control and emission patterns.
Implementation Method 1
The collection optics include a small reflective ring with reflective sidewalls that surrounds one or more LEDs
Implementation Method 2
The upper reflector includes reflective sidewalls that are an approximate continuation of the reflective sidewalls on the reflective ring when assembled
Data Source
Figure 1~2
Figure 3~5A
Figure 5B~6
AI summary
Collection optics (10) are used with one or more light emitting diodes (106) to produce, e.g., collimated light. The collection optics (10) are produced in multiple pieces including a small reflective ring (102) that surrounds the one or more light emitting diodes (106). The reflective ring (102) may be positioned relative to the LEDs (106), using a mesa (112) upon which the LEDs (106) are mounted, as a lateral positioning guide. A separate upper reflector (104) uses the reflective ring (102) as a lateral positioning guide during assembly. The reflective ring (102) and the upper reflector (104) include reflective sidewalls that are approximately continuous when the reflective ring (102) and upper reflector (104) are assembled.