Sensor Indicator Fluorophore Layer for Uniform Light Visibility
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Solution Overview
Problem
Industrial sensors face challenges in enhancing the visibility of their indicator lights, particularly when viewed from large off-center angles, due to light being reflected, scattered, or absorbed by the sensor housing and epoxy potting material, leading to dim and non-uniform illumination.
Innovation Solution
The use of a sensing device with a transparent or translucent indicator layer embedded with fluorophores, such as fluorescent dyes, nano-phosphors, or quantum dots, which absorb and re-emit light to enhance visibility, combined with a housing design that maximizes internal reflections and edge-glow effects, allowing light to be emitted from end walls around the perimeter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional light sources are used with epoxy potting material, then the sensor housing is protected and sealed, but the light visibility is significantly reduced due to scattering and absorption
Solution Approach 1:
The patent applies fluorescent materials that absorb light at one wavelength and emit at a different wavelength, transforming the light characteristics to achieve both visibility enhancement and housing protection. The fluorescent layer converts UV or blue light from the LED into visible spectrum light that can penetrate the epoxy potting material more effectively.
Solution Approach 2:
The patent uses a composite structure combining LED light source, fluorescent material layer, and epoxy potting material. This composite approach allows each material to perform its optimal function: the LED provides intense light, the fluorescent material enhances visibility by wavelength transformation, and the epoxy provides protection while allowing the transformed light to pass through.
2Illumination intensity
If brighter light sources are used to improve visibility, then the indicator becomes more visible, but the electric load on the base circuit increases
Solution Approach 1:
The patent changes the wavelength parameter of the light by using fluorescent materials that convert high-energy UV or blue light into lower-energy visible light. This parameter transformation allows the system to achieve high visibility with lower power consumption, as the fluorescent conversion is more energy-efficient than simply increasing the LED drive current.
Solution Approach 2:
The patent replaces the direct approach of increasing electrical power to the LED with an optical conversion approach using fluorescent materials. This substitution transforms the problem from an electrical power issue to an optical wavelength transformation issue, achieving visibility enhancement with minimal additional electric load.
3Illumination intensity
If physical optical structures such as prisms and light pipes are added, then light distribution is improved, but the device complexity and housing size increase
Solution Approach 1:
The patent merges the optical enhancement function directly into the existing epoxy potting material by incorporating fluorescent additives. This eliminates the need for separate optical components like prisms or light pipes, as the housing material itself performs the light distribution and enhancement function.
Solution Approach 2:
The epoxy potting material serves multiple functions: it provides mechanical protection and sealing for the LED, and simultaneously acts as an optical element for light distribution and enhancement through the fluorescent conversion. This multi-functionality eliminates the need for additional dedicated optical components.
4Illumination intensity
If larger light source components are used to improve visibility, then the indicator becomes brighter, but the housing size must be increased to accommodate them
Solution Approach 1:
The patent changes the efficiency parameter of the light conversion process by using fluorescent materials with high quantum efficiency. This allows a small LED to produce sufficient visible light output through wavelength transformation, eliminating the need for larger, less efficient light source components.
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 solution significantly improves the visibility and uniformity of sensor indicator lights, making them more visible from various angles without the need for brighter light sources or additional optical structures, thus overcoming the drawbacks of existing solutions.
Implementation Method 1
one or more fluorophores embedded in the indicator layer, a first light source for transmitting light into the indicator layer, wherein the transmitted light is reflected inside the indicator layer and absorbed by the fluorophore to generate enhanced light that is emitted from the end walls
Implementation Method 2
the transmitted light is reflected inside the indicator layer and absorbed by the fluorophore to generate enhanced light that is emitted from the end walls
Data Source
AI summary
Devices and methods for providing sensor indication are disclosed. The sensor device includes utilizing the signal to activate a light source, transmitting light into a first indicator layer with the light source, and the first indicator layer optionally includes a fluorophore. The indicator layer provides visibility of light around the sensor device.