Illuminated Sign Optical Path Conversion for LED Uniformity
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Solution Overview
Problem
Existing LED-based traffic signal lights require a large number of LEDs to achieve uniform light emission, increasing manufacturing costs and complexity due to the need for numerous contact points and careful selection of LEDs with similar brightness to avoid uneven light patterns.
Innovation Solution
The use of an optical path conversion component and a light uniformizing component to adjust light distribution, reducing the number of LEDs required while maintaining brightness and uniformity, by dispersing LEDs and using optical path conversion structures to collimate divergent light beams into parallel beams that are then adjusted to form a uniform light emission surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a large number of LEDs are arranged to form indicating patterns, then uniform light emission is achieved, but manufacturing cost and device complexity increase due to numerous contact points and assembly procedures
Solution Approach 1:
Multiple LEDs are integrated into a single LED module with shared contact points on the circuit substrate. The LED module combines multiple light emitting members that can be controlled independently through signal lines, reducing the number of contact points required while maintaining the ability to form various indicating patterns with uniform light emission.
Solution Approach 2:
The LED module serves multiple functions: it can form different indicating patterns (human shape, palm shape, traffic signals) by controlling different groups of LEDs within the module, and it provides uniform light emission across various patterns. The optical path conversion component also serves dual purposes of light collection and distribution uniformization.
2Illumination intensity
If LEDs with similar brightness are selected to avoid uneven light patterns, then light emission uniformity is improved, but the difficulty to choose LEDs increases
Solution Approach 1:
The optical path conversion component acts as an intermediary between the LEDs and the external environment. It collects light from multiple LEDs with different brightness characteristics and redistributes it uniformly, allowing the use of LEDs with varying brightness without affecting the final uniformity of the light pattern.
Solution Approach 2:
The optical path conversion component transforms the light parameters (direction, distribution) from the LEDs. By changing the optical path and light distribution characteristics, it compensates for differences in LED brightness, allowing broader selection of LEDs while maintaining uniform light emission patterns.
3Illumination intensity
If swarms of arranged LEDs are used to form indicating patterns, then the indicating pattern is visible, but the amounts of LEDs and manufacturing cost increase
Solution Approach 1:
Multiple LEDs are combined into integrated modules where several light emitting members work together to form complete indicating patterns. This reduces the total number of separate LED components needed while maintaining pattern visibility and recognition.
Solution Approach 2:
The optical path conversion component serves as an intermediary that collects and redistributes light from fewer LEDs to create visible indicating patterns. It amplifies the effective light output by optimizing light collection and distribution, reducing the total LED quantity required for pattern visibility.
4Reliability
If repeated assembly procedures are executed to weld LEDs to contact points, then proper LED mounting is achieved, but working complexity and manufacturing cost increase
Solution Approach 1:
Multiple LEDs are mounted together on the circuit substrate as integrated LED modules, reducing the number of separate welding operations. The module structure allows for more efficient assembly processes while maintaining reliable electrical and mechanical connections.
Solution Approach 2:
The LED module is pre-assembled with multiple light emitting members mounted and wired together before installation on the circuit substrate. This preliminary assembly reduces the complexity of on-site installation and ensures proper mounting reliability through standardized pre-tested connections.
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
This solution significantly reduces the number of LEDs needed, lowering manufacturing costs and simplifying the assembly process while ensuring that the brightness and uniformity of the light emission meet specification requirements, with examples showing a reduction from 120 LEDs to 28 for a palm shape and from 75 to 21 for a human shape.
Implementation Method 1
Each of the light emitting members generates a divergent light beam passing through the corresponding optical path conversion structures to collimate into a parallel light beam
Implementation Method 2
the parallel light beams are adjusted into non-parallel light beams through the light uniformizing component for forming a uniform light emission surface presenting the indicating pattern
Data Source
AI summary
The illuminated sign includes a frame defining a space, a light emitting module received in the space and having a plurality of light emitting members disposed on a circuit substrate, an optical path conversion component provided on the frame to correspond to the light emitting members, and a light uniformizing component positioned a distance above the optical path conversion component. The space is compartmented to form a predetermined pattern, projecting a desired signal when the light emitting members in different compartments of the space are selectively illuminated.