Car Lamp Light Source Unit With Dot Phosphors
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Solution Overview
Problem
Existing car lamps using packaged semiconductor light emitting devices have low mass production yield, high costs, and limited flexibility, with defective devices resulting in non-lighting regions.
Innovation Solution
A car lamp design featuring dot-shaped phosphors between semiconductor light emitting devices to create a point light source with a large area, eliminating non-lighting regions and allowing for flexible manufacturing without the need for defective device repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If package type light emitting diodes are used in car lamps, then the lighting function is achieved, but the mass production yield is low, cost is high, and flexibility is limited
Solution Approach 1:
The patent divides the light emitting structure into multiple semiconductor light emitting devices arranged in an array on a single substrate, replacing traditional packaged LEDs. This segmentation enables parallel manufacturing of multiple light sources simultaneously, significantly improving mass production yield while maintaining lighting functionality.
Solution Approach 2:
The patent creates a universal light emitting module that integrates multiple semiconductor light emitting devices, phosphor materials, and wiring electrodes on a single substrate. This multi-functional integration eliminates the need for separate packaged LEDs, reducing costs and improving manufacturing efficiency while providing flexibility in lamp design.
2Reliability
If package type light emitting diodes are used in car lamps, then the lighting function is achieved, but the cost is high
Solution Approach 1:
The patent merges multiple functional components (semiconductor light emitting devices, phosphor materials, wiring electrodes, and insulating materials) into a single integrated module. This consolidation eliminates the need for separate packaged LEDs and their associated mounting hardware, significantly reducing material costs and assembly complexity.
Solution Approach 2:
The patent transitions from three-dimensional packaged LEDs to a planar two-dimensional array of semiconductor light emitting devices on a substrate. This dimensional change enables more efficient use of materials, simplified manufacturing processes, and reduced overall cost while maintaining or improving lighting performance.
3Reliability
If package type light emitting diodes are used in car lamps, then the lighting function is achieved, but the flexibility is low
Solution Approach 1:
The patent creates a flexible light emitting module where semiconductor light emitting devices can be arranged in various patterns and configurations on the substrate. This dynamic arrangement capability allows the same basic module to be adapted for different lamp types and designs, significantly improving versatility and flexibility.
4Productivity
If defective semiconductor light emitting devices are present, then manufacturing continues, but non-lighting regions are exposed from the outside
Solution Approach 1:
The patent converts the potential harm of defective light emitting devices into a benefit by using phosphor materials that emit light when excited by surrounding functional devices. Instead of requiring repair or rejection of defective devices, the phosphor materials compensate for defects by emitting light from non-defective areas, maintaining lighting uniformity and eliminating visible non-lighting regions.
Solution Approach 2:
The patent incorporates phosphor materials in advance as a compensatory mechanism against potential defects in semiconductor light emitting devices. This beforehand cushioning ensures that even if defects occur during manufacturing or operation, the lighting uniformity is maintained through the light emission from phosphor materials, preventing non-lighting regions from appearing.
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 enables a car lamp with uniform brightness and reduced light emission deviations, even with defective devices, and simplifies manufacturing by eliminating the need for defective device repair, resulting in a cost-effective and flexible light source.
Implementation Method 1
a plurality of phosphor portions disposed on the plurality of semiconductor light emitting devices, and formed to convert the wavelength of light
Data Source
AI summary
A light source unit for a car lamp. The light source unit includes a substrate including wiring electrodes; a plurality of semiconductor light emitting devices electrically connected to the wiring electrodes; a plurality of phosphor portions spaced apart at preset intervals and arranged along rows and columns, and respectively disposed between the semiconductor light emitting devices so as to convert light emitted by surrounding semiconductor light emitting devices into second light having a second wavelength and to emit the second light; a light transmitting material filled between the phosphor portions and emitting first light having a first wavelength; and a color filter covering the phosphor portions and the light transmitting material and emitting the first light with the first wavelength and the second light with the second wavelength.