Integrated LED Light Bar for Planar Source Efficiency
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Solution Overview
Problem
Existing edge-lighting planar light source modules have inefficiencies due to the separation of LEDs from light guide plates, leading to reduced light illumination and high manufacturing costs, with limitations in power and heat dissipation, and complex processes.
Innovation Solution
Integrally forming LEDs within a light guide plate using a method where LEDs are disposed on molds and a polymerizable concoction is poured to create a unified structure, allowing for improved light entry and heat dissipation, and reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If LEDs are separated from light guide plates in conventional edge-lighting modules, then manufacturing and assembly are simplified, but light entry efficiency decreases and illumination is reduced
Solution Approach 1:
The patent integrates LEDs directly into the light guide plate structure, merging the light source and light guiding components into a unified integrated light bar. This eliminates the separation between LEDs and light guide plate, enabling light to enter the guide plate from within the structure rather than from the edge, thereby improving light entry efficiency while maintaining manufacturing simplicity through modular integration.
2Length of stationary object
If SMD LEDs with lower power are used to meet thickness restrictions, then the structure becomes thinner and more flexible, but light-emitting efficiency and heat dissipation deteriorate
Solution Approach 1:
The patent transitions from edge-lighting (two-dimensional surface mounting) to internal lighting (three-dimensional integration). By placing LEDs inside the light guide plate structure rather than on the surface edge, the design achieves thinness while accommodating higher-power LEDs that provide better light-emitting efficiency and heat dissipation performance.
3Illumination intensity
If many LEDs are required to achieve sufficient illumination, then brightness is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The integrated light bar structure serves multiple functions simultaneously: it provides structural support, guides light distribution, and houses the LED array. This multi-functionality reduces the number of separate components needed, simplifying manufacturing processes and reducing assembly complexity while maintaining sufficient brightness through optimized LED arrangement within the unified structure.
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 approach enhances light source efficiency by ensuring nearly complete light entry into the guide plate, improves heat dissipation, and lowers manufacturing costs, resulting in a more efficient and cost-effective planar light source.
Implementation Method 1
a polymerizable concoction is poured to create a unified structure
Implementation Method 2
The light, after being reflected by the reflector 24, scatters from the diffuser 22
Implementation Method 3
scatters from the diffuser 22 and is converted into the uniform surface light source
Implementation Method 4
after being reflected by the reflector 24
Data Source
AI summary
A LED light bar, a related planar light source and a method of manufacturing such light bar is provided. The light source includes a light guide plate having a first surface and a second surface; at least one light bar, on which a plurality of LEDs is disposed, wherein the light bar is disposed on a lateral side of the light guide plate, and the LEDs are disposed inside the light guide plate to output light; a reflector, which is disposed outside the second surface and reflects light; and a diffuser, which is disposed outside the first surface and scatters reflected light of the reflector. Because LEDs are pre-disposed in a mold when the light guide plate is manufactured, the LEDs and the light guide plate are integrally formed, the loss of light can be avoided, and the efficiency of the planar light source can be enhanced.