Light Emitting Module With Concave Light Guide Plate
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Solution Overview
Problem
Existing light source devices face challenges in achieving uniform luminance emission due to inadequate thinning and uneven light scattering from light emitting elements, limiting their application in requiring emission characteristics with less luminance unevenness.
Innovation Solution
A method for manufacturing a light emitting module involving a light emitter with a light-transmissive light guide plate having concave portions, where the light emitter is fixed to the bottom surface of the concave portion via a bonding member, and a wiring is formed at the electrode of the light emitting element, enhancing light extraction efficiency and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a distance between the mounting substrate and the diffusion member is larger than a thickness of the lens member, then light scattering uniformity is improved, but device thickness increases
Solution Approach 1:
The invention uses hemispherical lens members with curved surfaces instead of flat diffusers. The hemispherical shape refracts light in multiple directions, achieving uniform luminance distribution while maintaining a compact thickness that eliminates the need for a large air gap between the mounting substrate and diffusion member.
Solution Approach 2:
The invention introduces a reflective resin layer as an intermediary between the light emitting elements and the diffusion member. This reflective layer redirects light that would otherwise be lost, improving light utilization efficiency and enabling uniform luminance output without increasing device thickness.
2Ease of manufacture
If a two-layer sheet with sealing resin and phosphor is used, then manufacturing is simplified, but light scattering uniformity deteriorates
Solution Approach 1:
The invention separates the sealing function and light diffusion function into distinct components. The two-layer sheet structure is replaced by individual hemispherical lens members mounted on the substrate, with each lens serving both as a seal and a light-guiding element. This segmentation allows optimization of each component's function while maintaining manufacturing efficiency.
Solution Approach 2:
The hemispherical lens members perform multiple functions simultaneously: they seal the light emitting elements, guide light extraction, and contribute to uniform luminance distribution. This multi-functionality replaces the need for separate sealing resin and phosphor layers, simplifying the overall structure while improving optical performance.
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 method achieves a light emitting module with reduced luminance unevenness, enabling its use in applications requiring consistent emission characteristics while allowing for module thinning.
Implementation Method 1
a light-transmissive light guide plate having a first main surface serving as a light emitting surface from which light is emitted outside and a second main surface located opposite to the first main surface and having a concave portion
Implementation Method 2
the concave portion including a side surface and a bottom surface smaller than an opening of the concave portion in a cross-sectional view; fixing the light emitter to the bottom surface of the concave portion
Data Source
AI summary
In order to obtain a light emitting module with a less unevenness of luminance, provided is a method for manufacturing a light emitting module comprising: preparing a light emitter and a light-transmissive light guide plate, the light emitter comprising a light emitting element, the light guide plate having a first main surface serving as a light emitting surface from which light is emitted outside and a second main surface located opposite to the first main surface and having a concave portion, the concave portion comprising a side surface and a bottom surface that is smaller than an opening of the concave portion in a cross-sectional view; fixing the light emitter to the bottom surface of the concave portion via a bonding member; and forming a wiring at an electrode of the light emitting element.