Transparent Solder Mask LED Assembly Reflectivity
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Solution Overview
Problem
Conventional LEDs face inefficiencies due to heat management issues and light absorption, limiting their brightness and effectiveness in applications like flashlights and general illumination.
Innovation Solution
The development of LED assemblies with enhanced reflectivity, featuring machined cups and transparent solder masks, which improve heat dissipation and reduce light absorption, allowing for increased current usage and brightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If brighter LEDs are used to increase illumination intensity, then illumination intensity is improved, but heat generation increases which reduces LED efficiency
Solution Approach 1:
The patent converts the harmful heat generated by high-current LED operation into a beneficial feature by implementing a heat sink structure that actively manages thermal energy. The heat sink with fins and heat dissipation pathways transforms the waste heat into a controlled thermal management system, allowing the LED to operate at higher currents for increased brightness while maintaining efficiency through effective heat removal.
2Reliability
If conventional solder mask is used to protect substrate, then substrate protection is improved, but light reflectivity deteriorates due to absorption
Solution Approach 1:
The patent changes the optical parameter of the solder mask from opaque to transparent. By selecting a transparent solder mask material, the invention maintains the protective function of the solder mask while eliminating its light-absorbing property. This parameter change allows light to pass through the solder mask and be reflected by the underlying reflective layer, thereby reducing energy loss while preserving substrate protection.
3Illumination intensity
If more current is supplied to increase brightness, then illumination intensity is improved, but heat management becomes more difficult
Solution Approach 1:
The patent segments the heat dissipation function into multiple components: a heat sink base in direct contact with the LED, vertical fins for increased surface area, and heat dissipation pathways distributed throughout the structure. This segmentation of the thermal management system allows efficient heat removal at multiple levels, enabling the LED to operate at higher currents for increased brightness while maintaining effective temperature control.
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
These improvements result in brighter LEDs with enhanced heat management and reduced light loss, suitable for applications such as flashlights and general illumination.
Implementation Method 1
an LED assembly can comprise a transparent solder mask. The transparent solder mask can enhance reflectivity of the substrate (or of material formed upon the substrate)
Implementation Method 2
The transparent solder mask can enhance reflectivity of the substrate (or of material formed upon the substrate)
Implementation Method 3
The machined surface can be deep enough to define a cup or can be too shallow to define a cup. The machined surface can be deep enough to define a shallow cup. In any instance, the machined surface can be more reflective than a non-machined surface.
Data Source
AI summary
A substrate for an LED assembly can have a plurality of cups formed therein. At least one cup can be formed within another cup. The cups can be co-axial with respect to one another, for example. A machined surface of the substrate can enhance reflectivity of the LED assembly. A transparent and/or non-global solder mask can enhance reflectivity of the LED assembly. A transparent ring can enhance reflectivity of the LED assembly. By enhancing reflectivity of the LED assembly, the brightness of the LED assembly can be increased. Brighter LED assemblies can be used in applications such as flashlights, displays, and general illumination.