Continuous Wavelength Conversion Member for Uniform LED Light Beam
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Solution Overview
Problem
Existing light emitting devices with multiple LEDs on a circuitry substrate often produce non-uniform light intensity and color across their surface due to discontinuous wavelength conversion members and spacing issues, leading to undesirable shadows and color variations in applications like automotive headlamps.
Innovation Solution
A light emitting device featuring a circuitry substrate with coplanar flip chip LEDs, a continuous and planar wavelength conversion member, and a light shaper to ensure uniform electromagnetic radiation transmission and minimize scattered radiation, resulting in a uniform light beam with consistent color and intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple LEDs are spaced on a circuitry substrate with separate wavelength conversion members, then the device can be manufactured with simple processes, but the light beam produces non-uniform light intensity and color with gaps and shadows
Solution Approach 1:
The patent merges multiple separate wavelength conversion members into a single continuous wavelength conversion member that spans across multiple LED chips. This continuous member is applied as a uniform layer over the entire LED array, eliminating gaps and ensuring consistent light conversion across the beam width, thereby resolving the non-uniformity issue while maintaining manufacturing simplicity
Solution Approach 2:
The patent applies local quality by creating a continuous wavelength conversion layer with varying local thickness or composition to compensate for the spatial distribution of multiple LED chips. This ensures that each region of the light beam receives appropriate wavelength conversion to achieve overall uniformity, addressing the non-uniform light intensity and color caused by spaced LEDs
2Device complexity
If wavelength conversion members are discontinuous and spaced, then the device structure is simpler, but dark areas and shadows are formed in the light beam
Solution Approach 1:
The patent implements continuity of useful action by using a continuous wavelength conversion member that uninterrupted spans across the entire LED array. This continuous structure ensures that wavelength conversion occurs uniformly across the entire light beam width, eliminating the dark areas and shadows that result from discontinuous, spaced conversion members
3Reliability
If wire protection material is used to encapsulate electrical connection wires, then electrical connections are protected, but non-uniform brightness areas are created across the emitting surface
Solution Approach 1:
The patent extracts or removes the wire protection material from the light-emitting surface area. By eliminating this opaque material from the emitting surface, the patent prevents the creation of non-uniform brightness areas while maintaining electrical connection protection through alternative routing or protection methods that do not interfere with light output uniformity
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 a substantially uniform light intensity and color across the width of the light beam by using coplanar LEDs and a continuous planar wavelength conversion member, reducing gaps and shadows, and the light shaper enhances this uniformity by blocking scattered radiation.
Implementation Method 1
a continuous and substantially planar wavelength conversion member covering the light emitting diodes configured to convert the electromagnetic radiation emitted by the light emitting diodes into another wavelength range
Implementation Method 2
a planarized layer configured to support the wavelength conversion member on the circuitry substrate with a planar support surface that is coplanar to the top surfaces of the light emitting diodes
Implementation Method 3
a light shaper on the wavelength conversion member configured to shape the electromagnetic radiation transmitted through the wavelength conversion member and block scattered electromagnetic radiation from the wavelength conversion layer
Data Source
AI summary
A light emitting device includes a circuitry substrate and multiple light emitting diodes (LEDs) bonded to the circuitry substrate in a spaced array. The light emitting device also includes a continuous and substantially flat wavelength conversion member covering the light emitting diodes (LEDs) configured to convert the electromagnetic radiation emitted by the light emitting diodes (LEDs) into another wavelength range. The light emitting device also includes a planarized layer configured to support the wavelength conversion member on the circuitry substrate. The light emitting device can also include a light shaper on the wavelength conversion member configured to form emitting windows for the electromagnetic radiation transmitted through the wavelength conversion member forming an output light beam having a desired emitting window size, shape, and edge and to block and minimize scattered electromagnetic radiation from the wavelength conversion layer.