Automotive Lamp Resin Layer with Integrated Light Blocking
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Solution Overview
Problem
Existing lighting devices using LEDs face challenges in providing uniform surface light distribution and reducing hot spots due to the lack of effective light blocking mechanisms in the resin layer, which can lead to increased module thickness and reduced light intensity.
Innovation Solution
The lighting device incorporates a resin layer with integrated light blocking portions, including first, second, and third light blocking portions, and a reflective member to manage light emission and distribution, reducing transmittance and enhancing reflectance to improve light uniformity and reduce hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light blocking portions are added to the resin layer to reduce hot spots and improve light uniformity, then light distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The light blocking portions are integrated directly into the resin layer, merging the light blocking function with the sealing and structural resin layer. This eliminates the need for separate light blocking components, thereby improving light distribution uniformity while avoiding additional device complexity.
Solution Approach 2:
The resin layer is designed with localized light blocking portions at specific positions where hot spots occur. These light blocking portions have different optical properties (lower transmittance) compared to the surrounding resin, creating local quality variations that redirect light and improve overall uniformity without affecting the entire structure.
2Illumination intensity
If the resin layer thickness is increased to improve light blocking and reduce hot spots, then light uniformity is improved, but module thickness increases
Solution Approach 1:
Instead of uniformly increasing the resin layer thickness, the invention introduces localized light blocking portions within the existing thickness constraint. These portions create the necessary light redirection and uniformity improvement without requiring additional overall thickness, thus maintaining a compact module design.
Solution Approach 2:
The resin layer is functionally segmented into regions with different optical transmittance properties. The light blocking portions are distributed at specific locations to address hot spots, while the rest of the resin layer maintains its original thickness, achieving light uniformity without increasing the overall module thickness.
3Length of stationary object
If light blocking portions are integrated into the resin layer to reduce module thickness, then module thickness is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The light blocking portions are merged with the resin layer as an integrated structure, likely formed through the same molding or curing process. This integration reduces the need for separate manufacturing steps and alignment procedures, thereby reducing module thickness while mitigating the increase in manufacturing precision requirements that would result from assembling separate 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
The solution achieves reduced hot spots and improved optical reliability by minimizing transmittance and enhancing reflectance, allowing for thinner modules with uniform surface light distribution.
Implementation Method 1
a first light blocking portion integrally formed with the resin layer and having a transmittance lower than that of the resin layer on an emission-side region of each of the plurality of light emitting devices
Implementation Method 2
a reflective member disposed between the substrate and the resin layer
Data Source
AI summary
The lighting device disclosed in the embodiment of the invention includes a substrate; a plurality of light emitting devices disposed on the substrate and emitting light in at least a first direction; a resin layer sealing the plurality of light emitting devices; and an optical member disposed on the resin layer, wherein the resin layer may include a first light blocking portion integrally formed with the resin layer and having a transmittance lower than that of the resin layer on an emission-side region of each of the plurality of light emitting devices.