Tunable Integrated Optics LED Components with Reflective Encapsulant
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Solution Overview
Problem
Conventional LED arrays with transparent encapsulants face challenges in controlling and directing light output, leading to inefficiencies and increased costs due to the need for secondary optical devices.
Innovation Solution
The use of component-level integrated optics within the LED apparatus, which includes a light-transmissive encapsulation material and a reflective layer to control the direction and intensity of light emission, eliminating the need for external optical devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If secondary optical devices such as lenses are used to direct and control light output, then light directionality and control are improved, but device complexity and cost increase
Solution Approach 1:
The patent integrates the optical directing function directly into the encapsulant structure by forming a reflective layer and opening configuration within the encapsulant itself. This merging of the optical device function into the encapsulant eliminates the need for separate external lenses or optical components, thereby reducing device complexity while maintaining light directionality control.
Solution Approach 2:
The patent extracts the optical controlling function from external secondary optical devices and relocates it into the encapsulant structure. By taking out the need for separate lenses and integrating the optical control directly into the encapsulant's geometry (opening and reflective layer), the system simplifies the overall device architecture while achieving the desired light directionality.
2Illumination intensity
If secondary optical devices such as lenses are used to direct and control light output, then light focus and contrast are improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the optical focusing function with the encapsulant manufacturing process. By forming the reflective layer and opening directly within the encapsulant structure during encapsulation, the optical components are manufactured simultaneously with the encapsulant itself, eliminating the need for separate lens manufacturing and assembly steps, thereby reducing manufacturing cost.
Solution Approach 2:
The patent removes the need for separate external optical components and their associated manufacturing processes. By extracting the optical function and embedding it within the encapsulant structure, the manufacturing process is simplified to a single integrated process, reducing overall manufacturing cost while maintaining image sharpness.
3Illumination intensity
If secondary optical devices are used to control light emission, then light direction is improved, but energy efficiency decreases due to additional optical losses
Solution Approach 1:
The patent merges the light directing function into the encapsulant structure with minimal optical interfaces. By forming the reflective layer and opening directly within the encapsulant, the design eliminates multiple air-glass interfaces that would cause reflection and refraction losses, thereby improving energy efficiency while maintaining light direction control.
Solution Approach 2:
The patent utilizes the encapsulant's inherent optical properties and the reflective layer to redirect light that would otherwise be lost or scattered. By strategically positioning the reflective layer and opening, the design converts potentially wasted light into useful directed illumination, improving overall energy efficiency while achieving the desired light direction.
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 control and efficiency, reduces costs, and provides improved contrast and image sharpness by directing light through a defined viewing angle, while maintaining the reliability and brightness of LED packages.
Implementation Method 1
a reflective layer to control the direction and intensity of light emission
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~6B
AI summary
Light emitting diode (LED) devices and methods. An example apparatus can include a substrate, one or more LEDs, light-transmissive encapsulation material, and a reflective material covering a portion of the encapsulation material to form a defined opening. The opening allows light emitted from an LED to pass through in a prescribed manner. In some embodiments, the apparatus can be subsequently treated to modify the surface having the opening. In other embodiments, the reflective material can be disposed on a lateral surface of the encapsulation material to reflect light in a desired direction.