Tilted Emission LED Array with Offset Optical Centers
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Solution Overview
Problem
Existing LED systems face inefficiencies and increased costs due to the need for secondary optics to redirect light emission, which results in light loss and complex mounting configurations, especially when aiming to achieve specific light distribution patterns in applications like street lighting and displays.
Innovation Solution
The use of LED components with primary optics and custom chip placement, where the optical centers of LED chips and lenses are offset or tilted, allowing for controlled light emission profiles without the need for secondary optics, thereby reducing light loss and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If secondary optics are used to redirect light emission, then light distribution patterns can be achieved, but light loss increases and system complexity increases
Solution Approach 1:
The patent extracts the light redirection function from separate secondary optics and integrates it directly into the LED chip structure through tilted mounting. This eliminates the need for additional optical components that cause light loss, while maintaining the ability to achieve specific light distribution patterns.
Solution Approach 2:
The patent merges the light emission function with the light redirection function by tilting the LED chip mounting angle. This combines what were previously separate functions (emission from LED, redirection from secondary optics) into a single integrated solution, reducing light loss and system complexity.
2Illumination intensity
If secondary optics are used to redirect light emission, then light distribution patterns can be achieved, but device complexity increases
Solution Approach 1:
The patent removes secondary optics from the system entirely by integrating the redirection function into the LED chip mounting structure. This extraction of unnecessary components directly reduces device complexity while maintaining light distribution capabilities.
Solution Approach 2:
By merging the emission and redirection functions into a single tilted LED chip structure, the patent eliminates multiple separate components and their associated mounting complexities, resulting in a simpler overall system architecture.
3Ease of operation
If LED chips are mounted at tilted angles, then light emission can be directed at specific angles without secondary optics, but manufacturing precision requirements increase
Solution Approach 1:
The patent performs the light direction control action in advance by setting the LED chip mounting angle during the manufacturing process. This preliminary action of tilting the chips at specific angles allows for straightforward operation later without requiring complex adjustment mechanisms, while the precision is established during fabrication.
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 enhances light distribution efficiency, reduces costs, and enables a wider range of optical beam profiles, improving both economic and reliability aspects in various lighting applications by directly shaping the light emission without secondary optics.
Implementation Method 1
Light emitting diodes (LEDs) are solid state devices that convert electric energy to light, and generally comprise one or more active layers of semiconductor material sandwiched between oppositely doped layers. When a bias is applied across the doped layers, holes and electrons are injected into the active layer where they recombine to generate light.
Implementation Method 2
Each of the plurality of LED components comprises at least one LED chip on a mounting surface and an optical lens overlying the LED chip and having a lens base attached to the mounting surface.
Data Source
AI summary
The present disclosure is directed to LED components, and systems using such components, having a light emission profile that may be controlled independently of the lens shape by varying the position and/or orientation of LED chips with respect to one or both of an overlying lens and the surface of the component. For example, the optical centers of the LED emitting surface and the lens, which are normally aligned, may be offset from each other to generate a controlled and predictable emission profile. The LED chips may be positioned to provide a peak emission shifted from a perpendicular centerline of the lens base. The use of offset emitters allows for LED components with shifted or tilted emission patterns, without causing output at high angles of the components. This is beneficial as it allows a lighting system to have tilted emission from the LED component and primary optics.