Curved Vehicle Lamp PCB Layout for Durable Rear Light Distribution
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Solution Overview
Problem
Conventional vehicle rear lamps using light emitting diodes (LEDs) face durability issues due to stress from curvature and reduced light distribution, leading to increased costs from additional light sources to comply with light distribution laws.
Innovation Solution
A lighting device with a base member having a straight and curved portion, featuring a substrate with opaque and transparent materials, a resin layer, and a phosphor layer to optimize light emission and distribution, including a reflective member to enhance side-rear light efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the PCB substrate is given a curvature to match the lamp bracket structure, then the light source module can be formed to have a curved structure, but the durability of the module becomes weak and stress is applied to the PCB substrate and light source
Solution Approach 1:
The patent divides the light source module into multiple independent LED components mounted on a flat PCB substrate, rather than attempting to curve the entire substrate. This segmentation allows the substrate to remain flat and durable while the individual LED elements can be arranged to create the desired curved light pattern when illuminated.
Solution Approach 2:
The patent transitions from trying to curve the substrate in three-dimensional space to achieving the curved effect through two-dimensional arrangement of light sources on a flat plane. By positioning LEDs at different locations and angles on the flat substrate, the module creates a curved light distribution pattern without subjecting the substrate to mechanical stress.
2Adaptability or versatility
If the light source module is formed to have a curvature, then the design freedom of the lamp is increased, but the light distribution at the rear direction of the vehicle is reduced
Solution Approach 1:
The patent applies different optical properties to different regions of the light source module. By selectively positioning LEDs with different emission characteristics and using optical elements at specific locations, the module achieves both curved aesthetic design and optimized rearward light distribution. Each local region is tailored to contribute to both form and function.
Solution Approach 2:
The patent introduces optical elements such as lenses, reflectors, or diffusers as intermediaries between the LED light sources and the external environment. These intermediary components redirect and distribute light to ensure adequate rearward illumination while maintaining the curved aesthetic appearance of the light source module.
3Reliability
If additional light sources are attached to comply with light distribution law, then the light distribution requirement is met, but the cost increases
Solution Approach 1:
The patent designs the light source module so that the same LED components serve multiple functions: creating the curved aesthetic appearance and simultaneously providing the required rearward light distribution. By making each LED element multi-functional, the need for additional separate light sources is eliminated, reducing overall system complexity and cost.
Solution Approach 2:
The patent optimizes parameters such as LED emission angles, mounting positions, and optical element characteristics to maximize rearward light distribution from the existing light source module. By carefully adjusting these parameters, the module meets light distribution legal requirements without requiring additional light sources, thereby controlling costs.
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 improves durability and light efficiency, ensuring compliance with light distribution laws while reducing costs by using a substrate configuration that optimizes light emission and distribution.
Implementation Method 1
a phosphor layer disposed on the resin layer
Data Source
AI summary
A lighting device disclosed in the embodiment of the invention includes a base member including a straight portion and a curved portion, a substrate including a first substrate disposed on the straight portion of the base member and a second substrate disposed on the curved portion; a plurality of light sources disposed on each of the first and second substrates, a resin layer including a first resin portion disposed on the first substrate and a second resin portion surrounding the second substrate, and a phosphor layer disposed on the resin layer, and an outer side surface of the second resin portion may include a curved surface.