Plane light-emitting module and LED lamp thereof

Abstract

The invention provides a plane light-emitting module and an LED lamp thereof. Comprising a substrate and a microstructure array light guide plate, the edge of the substrate is provided with a convex annular positioning part, and the top of the annular positioning part is provided with at least one adjusting groove; according to the invention, the sealing adjusting piece is arranged in the adjusting groove, the sealing adjusting piece is pressed tightly when the micro-structure array light guide plate is put down, and the gap between the micro-structure array light guide plate and the top surface of the annular positioning part is filled and sealed by utilizing the elastic self-adaptive deformation of the sealing adjusting piece, so that the sealing effect of the micro-structure array light guide plate is improved. Dust is prevented from entering, dimensional tolerance among parts is compensated, and meanwhile the angle of the microstructure array light guide plate is adjusted through the elasticity of the sealing adjusting piece.

Description

Technical Field

[0001] This invention relates to the field of light-emitting module technology, and in particular to a planar light-emitting module and its LED lamp. Background Technology

[0002] A planar light-emitting module is a core optical device that integrates and shapes the optical characteristics of multiple point light sources (such as LEDs) to generate a uniform, parallel, and highly directional emitted light field. Such modules have significant application value in high-end lighting, backlight displays, and professional optical equipment, and their optical performance directly depends on the accuracy and long-term stability of the relative positions of the various optical components.

[0003] Currently, in the production of planar LED lighting devices with high uniformity and high directivity, a common method is to set up a support structure (such as a gasket or column) between the substrate and the light guide plate and directly bond them together with adhesive to integrate multiple point light sources into a uniform planar light source and control the light emission direction. However, this method suffers from difficulties in ensuring assembly accuracy and in finely adjusting the relative orientation (especially parallelism) of optical components before curing. This is mainly due to the adhesive's inability to effectively fix the position before curing and the lack of a mechanism for precise and independent leveling before curing. This results in the final assembly being prone to micron-level tilting or stress deformation, leading to poor light emission uniformity and beam parallelism, affecting lighting quality. Furthermore, uneven adhesive layer thickness can cause stress or poor sealing. Therefore, there is an urgent need for a planar light-emitting module and its LED lighting fixtures. Summary of the Invention

[0004] To address at least one of the aforementioned technical shortcomings, this invention provides a planar light-emitting module, comprising a substrate and a microstructure array light guide plate. The substrate has an outwardly protruding annular positioning portion at its edge, and at least one adjustment groove is formed at the top of the annular positioning portion. A sealing adjustment component is disposed within the adjustment groove. The sealing adjustment component is elastic and is used to seal and adaptively abut against the microstructure array light guide plate. A light-emitting array is disposed on the surface of the substrate. The microstructure array light guide plate is disposed outside the light-emitting array and is assembled with the annular positioning portion of the substrate via a connecting ring. A prism array corresponding to the light-emitting array is disposed on the microstructure array light guide plate for converting point light sources into parallel emitted light. The planar light-emitting module also includes a fine-tuning mechanism that acts on the microstructure array light guide plate to adjust the tilt angle of the microstructure array light guide plate relative to the substrate during assembly. A fixing seal is filled in the assembly gap between the connecting ring and the annular positioning portion.

[0005] Furthermore, the sealing adjustment component is a silicone sealing strip, rubber sealing strip, or metal spring with longitudinal elasticity, the top shape of which is adapted to the lower edge surface of the microstructure array light guide plate.

[0006] Furthermore, the fine-tuning mechanism includes: a U-shaped frame fixed to the substrate or external mounting structure; a limiting cylinder fixedly connected to the U-shaped frame; an adjustment plate connected to the back of the microstructure array light guide plate; and a limiting rod connecting the adjustment plate and the limiting cylinder; wherein, an adjustment bolt is rotatably connected to the U-shaped frame, and the adjustment bolt is threadedly connected to a threaded hole on the adjustment plate.

[0007] Furthermore, four fine-tuning mechanisms are provided, each corresponding to one of the four corners of the planar light-emitting module, to achieve stable multi-point leveling of the microstructure array light guide plate.

[0008] Furthermore, the prism array consists of multiple convex or concave prism microstructures set on the light-emitting surface of the microstructure array light guide plate, and their arrangement density or shape is designed accordingly based on the arrangement of light sources and light intensity distribution in the light-emitting array.

[0009] Furthermore, the prism units of the prism array have a triangular, trapezoidal, or arc-shaped cross-section, and their apex angle or radius of curvature is configured such that the light emitted from the light-emitting array is refracted to form a parallel beam with a preset divergence angle.

[0010] Furthermore, the fixing seal is a sealant that forms a rigid or semi-rigid connection after curing. It fills and solidifies between the inner wall of the connecting ring and the outer wall of the annular positioning part, as well as between the lower surface of the edge of the microstructure array light guide plate and the top surface of the annular positioning part, to achieve permanent fixing and sealing.

[0011] Furthermore, the light-emitting array can be an LED chip array, a Mini LED chip array, or a Micro LED chip array.

[0012] An LED lighting fixture, characterized in that it includes a planar light-emitting module as described in any one of claims 1 to 8, and a driving power supply for powering the light-emitting array.

[0013] Furthermore, the LED lighting fixtures are LED panel lights, LED downlights, LED table lamps, or recessed linear lighting fixtures, with the planar light-emitting module mounted on the fixture housing or bracket via a substrate. Beneficial effects

[0014] By placing the sealing adjustment component into the adjustment groove and pressing it against the microstructure array light guide plate when it is lowered, the elastic adaptive deformation of the sealing adjustment component fills and seals the gap between the microstructure array light guide plate and the top surface of the annular positioning part, preventing dust from entering and compensating for dimensional tolerances between parts. At the same time, the elasticity of the sealing adjustment component is used to adjust the angle of the microstructure array light guide plate.

[0015] The tilt angle of the microstructure array light guide plate is precisely adjusted by operating the fine-tuning mechanism to ensure that its light-emitting surface is strictly parallel to the light-emitting surface of the substrate, and to ensure the relative positional accuracy between optical elements before injecting the fixing seal.

[0016] By pre-sealing the sealing adjustment component and leveling the fine-tuning mechanism, the relative positional accuracy between optical elements is ensured before curing, and the overall structure is stable after curing, thereby ensuring the uniformity and parallelism of the emitted light field.

[0017] By using a silicone sealing strip as a sealing adjustment component, when it is pressed down by the microstructure array light guide plate, the elastic deformation generates a rebound force that ensures the top of the sealing strip is always tightly pressed against the bottom surface of the microstructure array light guide plate. This fills the tiny gaps that may be caused by machining tolerances or assembly gaps between the two, achieving a preliminary seal before injecting the fixed sealing component. This effectively prevents dust from entering the light-emitting cavity during subsequent operations.

[0018] The elasticity of the sealing adjustment component provides a buffer, avoiding stress concentration or damage that may occur when the microstructure array light guide plate comes into direct contact with the rigid substrate. At the same time, the elasticity can be used to fine-tune the angle of the microstructure array light guide plate.

[0019] By rotating the adjusting bolt, the adjusting plate is moved, thereby precisely and steplessly adjusting the height of the corresponding angle of the microstructure array light guide plate. The combination of the limiting rod and the limiting cylinder ensures the uniformity and stability of the movement direction during the adjustment process, avoiding horizontal deflection of the microstructure array light guide plate, thus accurately controlling its parallelism with the substrate.

[0020] By setting a fine-tuning mechanism at each of the four corners of the planar light-emitting module, and by repeatedly and alternately fine-tuning the four adjusting bolts, the pitch and torsion attitude of the microstructure array light guide plate in three-dimensional space is precisely controlled until the entire light-emitting surface reaches the ideal horizontal state. This multi-point leveling structure provides over-constrained stable support, which can effectively resist the warping deformation of the microstructure array light guide plate that may be caused by its own weight or temperature changes, and ensure the consistency of the relative distance and angle between the prism array and the light-emitting array in the entire light-emitting area.

[0021] By setting a prism array on the light-emitting surface of the microstructure array light guide plate, light rays are emitted from the light-emitting array, enter the interior of the light guide plate, and then propagate to the interface of the prism array where they are refracted. By controlling the geometry and spatial distribution of each prism, the refraction position and direction of light rays on the light-emitting surface can be managed. Customized optical design can be carried out for specific light source layouts to compensate for the light intensity non-uniformity of individual point light sources, thereby achieving a highly uniform illuminance distribution on the light-emitting surface and expanding the point light source into a surface light source.

[0022] By designing the cross-section of the prism unit of the prism array to a specific shape and precisely designing its apex angle and bevel angle, the refraction angle of light at the prism interface is controlled. This allows light rays incident from different positions and with different initial angles to have their outgoing direction corrected to a very small angle range perpendicular to the normal of the light-emitting surface after refraction. This efficiently converts the Lambertian light emission mode of the LED point light source into a clearly directional parallel beam, improving light energy utilization and reducing glare.

[0023] By injecting and curing the adhesive for fixing the sealant into the annular gap between the connecting ring and the annular positioning part, the cured sealing material is firmly bonded to each component, permanently fixing the precisely leveled microstructure array light guide plate and the substrate together. This eliminates the possibility of slight positional changes caused by factors such as vibration and temperature cycling, ensuring the long-term stability of optical performance, and providing a final airtight barrier that effectively prevents dust and moisture.

[0024] By setting the light-emitting array to a high-density Mini LED or Micro LED chip array, combined with a precise prism array design, more delicate and uniform backlighting or direct-lit light emission can be generated, providing a reliable and controllable light source foundation for the entire planar light-emitting module.

[0025] By modularizing the planar light-emitting module and the driver power supply, the planar light-emitting module is responsible for efficient and high-quality optical output, while the driver power supply is responsible for stable and safe power supply and regulation, which facilitates the assembly, maintenance and upgrading of the lamp.

[0026] By integrating planar light-emitting modules as a standardized optical engine into different types of LED luminaires, planar light-emitting modules provide excellent and consistent basic optical performance, enabling manufacturers to quickly develop end-use luminaire products with different appearances, sizes and application scenarios based on this module, shortening the development cycle and ensuring the optical quality of the final luminaire.

[0027] The realization of the purpose, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0029] Figure 2 This is an isometric view of the substrate of the present invention.

[0030] Figure 3 This is an isometric view of the microstructure array light guide plate of the present invention.

[0031] Figure 4 This is an isometric view of the fine-tuning mechanism of the present invention.

[0032] Figure 5 This is a cross-sectional view of the fine-tuning mechanism of the present invention.

[0033] Figure 6 This is the invention Figure 5 Enlarged view of point A.

[0034] exist Figures 1 to 6 The correspondence between the component names or lines and the attached drawing numbers is as follows: substrate 1, outer convex ring 11, adjustment groove 12, sealing adjustment component 13, light-emitting array 14, microstructure array light guide plate 2, connecting ring 21, prism array 22, fine adjustment mechanism 3, U-shaped frame 31, limiting cylinder 311, adjustment plate 32, limiting rod 321, adjusting bolt 33, fixing seal 4. Detailed Implementation

[0035] Combined with appendix Figures 1 to 6 A planar light-emitting module includes a substrate 1 and a microstructure array light guide plate 2. The edge of the substrate 1 is provided with an outwardly protruding annular positioning part 11, and the top of the annular positioning part 11 is provided with at least one adjustment groove 12. A sealing adjustment member 13 is provided in the adjustment groove 12. The sealing adjustment member 13 is elastic and is used to seal and adaptively abut against the microstructure array light guide plate 2. A light-emitting array 14 is provided on the surface of the substrate 1. The microstructure array light guide plate 2 is disposed outside the light-emitting array 14 and is assembled with the annular positioning part 11 of the substrate 1 through a connecting ring 21. A prism array 22 corresponding to the light-emitting array 14 is provided on the microstructure array light guide plate 2 for converting point light sources into parallel emitted light. The planar light-emitting module also includes a fine-tuning mechanism 3, which acts on the microstructure array light guide plate 2 for adjusting the tilt angle of the microstructure array light guide plate 2 relative to the substrate 1 during assembly. A fixing seal 4 is filled in the assembly gap between the connecting ring 21 and the annular positioning part 11.

[0036] In practice, the sealing adjustment member 13 is placed into the adjustment groove 12 at the top of the annular positioning part 11 of the substrate 1. The microstructure array light guide plate 2 is fitted onto the outside of the annular positioning part 11 of the substrate 1 via its edge connecting ring 21, aligning the inner surface of the microstructure array light guide plate 2 with the light-emitting array 14 on the surface of the substrate 1. During the lowering of the microstructure array light guide plate 2, its lower edge surface presses against the sealing adjustment member 13. The elasticity of the sealing adjustment member 13 allows it to self-deform, thereby filling and sealing the gap between the microstructure array light guide plate 2 and the top surface of the annular positioning part 11, preventing dust from entering and compensating for dimensional tolerances between components. The fine-tuning mechanism 3 is operated to precisely adjust the tilt angle of the microstructure array light guide plate 2, ensuring that its light-emitting surface is strictly parallel to the light-emitting surface of the substrate 1. After the tilt angle is adjusted, the adhesive for fixing the sealing component 4 is injected into the annular gap between the inner wall of the connecting ring 21 and the outer wall of the annular positioning part 11. After it cures, the microstructure array light guide plate 2, the substrate 1 and the sealing adjustment component 13 are permanently fixed into a whole.

[0037] The light emitted by the light-emitting array 14 enters the microstructure array light guide plate 2 perpendicularly, and is refracted by the prism array 22 inside it, and is converted into parallel outgoing light. Through the pre-sealing of the sealing adjustment component 13 and the leveling of the fine adjustment mechanism 3, the relative positional accuracy between the optical elements is ensured before curing, and the overall structure is stable after curing, thereby ensuring the uniformity and parallelism of the outgoing light field.

[0038] Furthermore, the sealing adjustment element 13 is a silicone sealing strip, rubber sealing strip, or metal spring with longitudinal elasticity, and its top shape is adapted to the lower edge surface of the microstructure array light guide plate 2.

[0039] In a specific implementation, the sealing adjustment component 13 is described using a silicone sealing strip as an example. The silicone sealing strip has a hollow cylindrical or solid mushroom-shaped cross-section, and its bottom dimension matches the width of the adjustment groove 12, allowing it to be pressed in and stably locked within the adjustment groove 12. Its top is designed as a flat or slightly convex arc surface to form a surface contact with the smooth bottom surface of the microstructure array light guide plate 2. When the microstructure array light guide plate 2 is fitted onto the annular positioning part 11 via the connecting ring 21 and gradually pressed down, its bottom edge first contacts the top of the silicone sealing strip. As the pressure continues to decrease, the silicone sealing strip is compressed longitudinally (in the direction perpendicular to the surface of the substrate 1), and the rebound force generated by its elastic deformation ensures that the top of the sealing strip always tightly abuts against the bottom surface of the microstructure array light guide plate 2, thereby filling the tiny gaps that may be caused by processing tolerances or assembly clearances between the two. Before the injection of the fixing seal 4, a preliminary seal has been achieved, which effectively prevents dust from entering the light-emitting cavity during subsequent operations. At the same time, its elasticity provides a buffer, avoiding stress concentration or damage that may occur if the microstructure array light guide plate 2 comes into direct contact with the rigid substrate 1. The elasticity can also be used to adjust the angle of the microstructure array light guide plate 2.

[0040] Furthermore, the fine-tuning mechanism 3 includes: a U-shaped frame 31 fixed on the substrate 1 or an external mounting structure; a limiting cylinder 311 fixedly connected to the U-shaped frame 31; an adjustment plate 32 connected to the back of the microstructure array light guide plate 2; and a limiting rod 321 connecting the adjustment plate 32 and the limiting cylinder 311; wherein, an adjustment bolt 33 is rotatably connected to the U-shaped frame 31, and the adjustment bolt 33 is threadedly connected to the threaded hole on the adjustment plate 32.

[0041] In practice, the U-shaped frame 31 is secured to the corner of the substrate 1 or to the external mounting structure of the lamp. The adjusting plate 32 rests on the back of the microstructure array light guide plate 2. One end of the limiting rod 321 is fixed to the adjusting plate 32, and the other end is inserted into the limiting cylinder 311 on the U-shaped frame 31 with a certain fitting gap. This connection method allows the adjusting plate 32 to move the microstructure array light guide plate 2 within a small range along the axial direction (i.e., the leveling direction) of the limiting cylinder 311, but restricts its rotation in the horizontal plane. The adjusting bolt 33 passes through the middle of the U-shaped frame 31, and its end engages with the threaded hole on the adjusting plate 32. When it is necessary to adjust the height of a certain corner of the microstructure array light guide plate 2, the operator uses a tool to rotate the adjusting bolt 33. When rotated clockwise, the adjusting bolt 33 pushes the adjusting plate 32, thereby causing the corresponding position of the microstructure array light guide plate 2 to move away from the substrate 1 (lifting); when rotated counterclockwise, the pushing force of the adjusting bolt 33 on the adjusting plate 32 decreases, and under the action of the gravity of the microstructure array light guide plate 2 itself or other diagonal fine adjustment mechanisms 3, this position can move closer to the substrate 1 (lowering). Fine and stepless tilt adjustment is achieved through threaded transmission. The cooperation between the limiting rod 321 and the limiting cylinder 311 ensures the uniformity and stability of the movement direction during the adjustment process, avoiding horizontal deflection of the microstructure array light guide plate 2, thereby accurately controlling the parallelism between the microstructure array light guide plate 2 and the substrate 1.

[0042] Furthermore, four fine-tuning mechanisms 3 are provided, each corresponding to one of the four corner positions of the planar light-emitting module, to achieve stable multi-point leveling of the microstructure array light guide plate 2.

[0043] In practical implementation, the four fine-tuning mechanisms 3 work in the following way: During assembly, the U-shaped frames 31 of the four fine-tuning mechanisms 3 are first fixed near the four corners of the substrate 1, or the entire module is pre-installed on the external frame, and the four U-shaped frames 31 are fixed at the four corners of the frame. The four adjustment plates 32 are respectively fixed to the corresponding four corner areas on the back of the microstructure array light guide plate 2. The microstructure array light guide plate 2 is initially placed so that its connecting ring 21 is fitted onto the annular positioning part 11 of the substrate 1, and the four limiting rods 321 are respectively inserted into the corresponding limiting cylinders 311. At this time, the four adjusting bolts 33 are all in a state of no pressure. The leveling operation usually starts from one corner. For example, first adjust the adjusting bolt 33 of the upper left corner, observe the rise of that angle, and then adjust the adjusting bolts 33 of the upper right corner, lower left corner, and lower right corner in sequence. By repeatedly and alternately fine-tuning the four adjusting bolts 33, the pitch and torsion attitude of the microstructure array light guide plate 2 in three-dimensional space can be precisely controlled until its entire light-emitting surface reaches an ideal horizontal state and remains parallel to the plane of the light-emitting array 14 on the substrate 1. The specific benefits of this multi-point leveling structure are that it provides over-constrained stable support, effectively resisting the warping deformation of the microstructure array light guide plate 2 that may be caused by its own weight or temperature changes, ensuring the consistency of the relative distance and angle between the prism array 22 and the light-emitting array 14 throughout the entire light-emitting area, forming a uniform and parallel emitted light field.

[0044] Furthermore, the prism array 22 consists of multiple convex or concave prism microstructures disposed on the light-emitting surface of the microstructure array light guide plate 2, and its arrangement density or shape is designed accordingly based on the arrangement of the light sources and the light intensity distribution in the light-emitting array 14.

[0045] In practical implementation, the light-emitting surface of the microstructure array light guide plate 2 is formed with densely arranged prism microstructures through precision machining. The size of each prism microstructure is on the order of micrometers to millimeters. In specific designs, if the light-emitting array 14 consists of uniformly arranged LED chips, the prism array 22 is typically uniformly distributed across the entire light-emitting surface.

[0046] If the light-emitting array 14 is arranged in a non-uniform manner, or if the light intensity of the light source is high in certain areas, the parameters can be adjusted in the design of the prism array 22 in the corresponding areas.

[0047] For example, in the area directly above the center of the LED chip, the distribution density of prisms can be appropriately increased to extract and refract light more efficiently; or in areas with strong light intensity, prism units with slightly larger apex angles can be used to control the refraction angle of the light and avoid local over-brightness.

[0048] Light rays emerge from the light-emitting array 14 and enter the interior of the microstructure array light guide plate 2. When the light rays reach the interface of the prism array 22, they are refracted. By controlling the geometry and spatial distribution of each prism, the refraction position and direction of the light rays at the light-emitting surface can be managed. Customized optical designs can be performed for specific light source layouts to compensate for the light intensity non-uniformity of individual point light sources, thereby achieving a highly uniform illuminance distribution on the light-emitting surface and expanding the point light source into a surface light source.

[0049] Furthermore, the prism units of the prism array 22 have a triangular, trapezoidal, or arc-shaped cross-section, and their apex angle or radius of curvature is configured such that the light emitted from the light-emitting array 14 forms a parallel beam with a preset divergence angle after refraction.

[0050] In practical implementation, the optical operation process is illustrated using a prism unit with a triangular cross-section as an example.

[0051] Assume that the LED chips in the light-emitting array 14 emit light with a certain divergence angle, and this light is incident on the light-incident surface (bottom surface) of the microstructure array light guide plate 2 at different angles.

[0052] As light propagates inside the light guide plate, when it reaches the inclined surface of the triangular prism unit on the top surface, since it travels from an optically denser medium (light guide plate material, such as PC or PMMA) to an optically less dense medium (air), if the angle of incidence is greater than the critical angle, most of the light will undergo total internal reflection and continue to propagate; while some of the light that meets the refraction condition will pass through.

[0053] By precisely designing the apex angle and bevel angle of a triangular prism, the refraction angle of light at the prism interface can be controlled.

[0054] The goal is to ensure that light rays incident on the prism from different positions and with different initial angles are refracted so that their exit direction is corrected to a very small angle range (e.g., within ±10 degrees) perpendicular to the normal of the light-emitting surface. In this way, the light rays emitted from the entire module are macroscopically approximated as a parallel beam, and its divergence angle (beam width) is determined by parameters such as the prism's apex angle.

[0055] It can efficiently convert the Lambertian light emission mode of LED point light sources into a clearly directional parallel beam, which is crucial for occasions requiring directional lighting (such as table lamps, spotlights, and directional lighting panels), as it can improve light energy utilization and reduce glare.

[0056] The prism units of prism array 22 are configured according to different light sources.

[0057] Furthermore, the fixing seal 4 is a sealant that forms a rigid or semi-rigid connection after curing. It fills and solidifies between the inner wall of the connecting ring 21 and the outer wall of the annular positioning part 11, as well as between the lower surface of the edge of the microstructure array light guide plate 2 and the top surface of the annular positioning part 11, in order to achieve permanent fixing and sealing.

[0058] In practice, after adjusting the tilt angle of the microstructure array light guide plate 2 using the fine-tuning mechanism 3 and confirming that its position and orientation meet the requirements, a fixing and sealing operation is performed. The selected fixing seal 4 is a two-component epoxy resin adhesive or a UV-curable adhesive. The adhesive is slowly injected through the injection hole on the connecting ring 21 (the injection hole can be opened during installation or production) using a dispensing device. The adhesive fills the entire annular gap between the inner wall of the connecting ring 21 and the outer wall of the annular positioning part 11. Due to the presence of the sealing adjustment part 13, the adhesive is usually blocked in the top surface gap area of ​​the annular positioning part 11, but a small amount of adhesive may still penetrate around the sealing adjustment part 13, further enhancing the seal. After the adhesive completely fills the assembly gap, depending on the type of adhesive selected, it is cured by static room temperature curing, accelerated curing by heating, or UV irradiation, causing the adhesive to change from a liquid to a solid state. The cured fixing seal 4 is firmly bonded to the connecting ring 21, the annular positioning part 11, and the edge of the microstructure array light guide plate 2, forming a rigid or semi-rigid connection. The precisely leveled microstructure array light guide plate 2 is permanently bonded to the substrate 1, eliminating the possibility of slight positional changes due to factors such as vibration and temperature cycling, thus ensuring long-term stability of optical performance. Simultaneously, the cured sealant provides a final airtight barrier, effectively preventing dust and moisture.

[0059] Furthermore, the light-emitting array 14 is an LED chip array, a Mini LED chip array, or a Micro LED chip array.

[0060] In practical implementation, multiple LED chips (which can be ordinary LEDs, Mini LEDs, or Micro LEDs) are arranged and fixed in a matrix on the surface of substrate 1 using surface mount technology (SMT) or chip-level packaging processes. Substrate 1 is a printed circuit board with internal circuit traces to provide electrical connections for each LED chip or group of LED chips. These LED chips are connected to the circuitry on substrate 1 via wire bonding or flip-chip bonding. When using Mini LED or Micro LED chips, due to their smaller chip size (Mini LED chips have a side length of approximately 100-500 micrometers, and Micro LEDs are less than 100 micrometers), more light sources can be integrated within a unit area, forming a higher-density light-emitting array 14. The driving current is supplied to the light-emitting array 14 through the circuitry on substrate 1, illuminating all the LED chips and forming a uniform surface light source. Different types of light-emitting arrays 14 work in conjunction with prism arrays 22. The high-density Mini / Micro LED array, combined with a precise prism design, can produce finer, more uniform backlighting or direct-lit light emission. The light-emitting array 14, as a light source, has the characteristics of high brightness, long life and dynamic dimming, providing a reliable and controllable light source foundation for the entire planar light-emitting module.

[0061] An LED luminaire includes a planar light-emitting module and a driving power supply for powering a light-emitting array 14.

[0062] In practical implementation, LED luminaires consist of two main parts: the optical core component, the planar light-emitting module, and the electrical core component, the driver power supply. The driver power supply is typically an independent electronic module. Its input is connected to an external AC mains power supply (e.g., 220V / 50Hz), and internally undergoes rectification, filtering, and constant current control circuitry. The output of the driver power supply is connected via wires to the circuit interface on the substrate 1 of the planar light-emitting module, providing a constant DC operating current conforming to its electrical specifications to the light-emitting array 14. When the luminaire is powered on, the driver power supply starts working, and the light-emitting array 14 is illuminated. The light emitted by the light-emitting array 14 is collected by the microstructure array light guide plate 2 and refracted and shaped by the prism array 22, then emitted as a parallel beam from the front of the luminaire, providing illumination. The specific advantage of this structure is that it achieves the separation of functional modules: the planar light-emitting module is responsible for efficient and high-quality optical output, while the driver power supply is responsible for stable and safe power supply and regulation. This modular design facilitates the assembly, maintenance, and upgrading of the luminaire.

[0063] Furthermore, the LED luminaire is an LED panel light, LED downlight, LED table lamp or recessed linear luminaire, and the planar light-emitting module is mounted on the luminaire housing or bracket via substrate 1.

[0064] In practical implementation, in LED panel lights, the planar light-emitting module is a whole unit. Its substrate 1 is fixed to the metal or plastic back plate of the lamp by screws or clips. The entire module is then covered with a diffuser plate and then fitted with a frame to form a complete flat panel lamp.

[0065] In LED downlights, the substrate 1 of the planar light-emitting module is mounted on the top of the downlight's heat dissipation housing, with its light emission direction aligned with the downlight's reflector or lens. The parallel light emitted by the module is distributed downwards after secondary light distribution.

[0066] In LED desk lamps, the substrate 1 of the planar light-emitting module is fixed inside the lamp head bracket at the end of the lamp arm, while the driver power supply can be placed in the lamp base. The two are connected by wires passing through the lamp arm. In recessed linear luminaires, multiple strip-shaped planar light-emitting modules can be arranged side by side, with their substrate 1 fixed on a long strip-shaped aluminum profile heat sink, together forming a continuous light-emitting surface. Regardless of the form, the planar light-emitting module is integrated as a standardized optical engine. The specific benefits of this integration method are that the planar light-emitting module provides excellent and consistent basic optical performance (parallel light, uniformity). Luminaire manufacturers can quickly develop end-product luminaires with different appearances, sizes, and application scenarios based on this module, shortening the development cycle and ensuring the optical quality of the final luminaire.

Claims

1. A planar light-emitting module, comprising a substrate (1) and a microstructure array light guide plate (2), characterized in that: The substrate (1) has an outwardly protruding annular positioning part (11) at its edge, and at least one adjustment groove (12) is provided on the top of the annular positioning part (11); a sealing adjustment member (13) is provided in the adjustment groove (12), and the sealing adjustment member (13) is elastic and is used to seal and adaptively abut against the microstructure array light guide plate (2); a light-emitting array (14) is provided on the surface of the substrate (1), and the microstructure array light guide plate (2) is disposed outside the light-emitting array (14) and connected to the annular positioning part (1) of the substrate (1) through a connecting ring (21). The positioning part (11) is fitted and assembled; the microstructure array light guide plate (2) is provided with a prism array (22) corresponding to the light emission array (14) to convert the point light source into parallel emitted light; the planar light emission module also includes a fine adjustment mechanism (3), which acts on the microstructure array light guide plate (2) to adjust the tilt angle of the microstructure array light guide plate (2) relative to the substrate (1) during assembly; the assembly gap between the connecting ring (21) and the annular positioning part (11) is filled with a fixing seal (4).

2. The planar light-emitting module according to claim 1, characterized in that: The sealing adjustment element (13) is a silicone sealing strip, rubber sealing strip or metal spring with longitudinal elasticity, and its top shape is adapted to the lower edge surface of the microstructure array light guide plate (2).

3. A planar light-emitting module according to claim 1, characterized in that: The fine-tuning mechanism (3) includes: a U-shaped frame (31) fixed on the substrate (1) or an external mounting structure; a limiting cylinder (311) fixedly connected to the U-shaped frame (31); an adjustment plate (32) connected to the back of the microstructure array light guide plate (2); and a limiting rod (321) connecting the adjustment plate (32) and the limiting cylinder (311); wherein, an adjustment bolt (33) is rotatably connected on the U-shaped frame (31), and the adjustment bolt (33) is threadedly connected to the threaded hole on the adjustment plate (32).

4. A planar light-emitting module according to claim 3, characterized in that: The fine-tuning mechanism (3) is provided in four parts, and is respectively set at the four corners of the planar light-emitting module to achieve stable multi-point leveling of the microstructure array light guide plate (2).

5. A planar light-emitting module according to claim 1, characterized in that: The prism array (22) consists of multiple protruding or recessed prism microstructures disposed on the light-emitting surface of the microstructure array light guide plate (2). The arrangement density or shape of the prisms is designed according to the arrangement of the light sources and the light intensity distribution in the light-emitting array (14).

6. A planar light-emitting module according to claim 5, characterized in that: The prism unit of the prism array (22) has a triangular, trapezoidal or arc-shaped cross-section, and its apex angle or radius of curvature is configured such that the light emitted from the light-emitting array (14) is refracted to form a parallel beam with a preset divergence angle.

7. A planar light-emitting module according to claim 1, characterized in that: The fixed seal (4) is a sealant that forms a rigid or semi-rigid connection after curing. It fills and solidifies between the inner wall of the connecting ring (21) and the outer wall of the annular positioning part (11), as well as between the lower surface of the edge of the microstructure array light guide plate (2) and the top surface of the annular positioning part (11), in order to achieve permanent fixation and sealing.

8. A planar light-emitting module according to claim 1, characterized in that: The light-emitting array (14) is an LED chip array, a Mini LED chip array, or a Micro LED chip array.

9. An LED lighting fixture, characterized in that, It includes a planar light-emitting module as described in any one of claims 1 to 8, and a driving power supply for powering the light-emitting array (14).

10. The LED lamp according to claim 9, characterized in that, The LED lamp is an LED panel lamp, LED downlight, LED table lamp or recessed linear lamp, and the planar light-emitting module is mounted on the lamp housing or bracket through the substrate (1).

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