LED Array Curved Wave Grooves for Illuminance Evenness
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Solution Overview
Problem
Existing LED arrays exhibit uneven illuminance due to straight no-light-emitting areas between LED elements, which can result in visible dark portions when used in applications like automobile headlights.
Innovation Solution
The LED array features a recessed and protruding configuration on the side faces of adjacent light emitting sections, forming a curved wave shape that reduces linear gaps and increases light scattering, thereby enhancing evenness of illuminance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If straight intervals are maintained between LED elements for mounting accuracy, then manufacturing precision is improved, but illuminance evenness deteriorates due to linear no-light-emitting areas
Solution Approach 1:
The patent applies curvature by forming groove portions with curved wave shapes between adjacent light emitting sections. These curved grooves replace straight intervals, causing light to scatter in multiple directions rather than creating linear dark areas. The curved geometry maintains the necessary spacing for mounting accuracy while eliminating the harmful linear no-light-emitting zones that cause illuminance unevenness.
2Quantity of substance
If LED elements are arranged in series to ensure luminous flux, then light output is improved, but the linear arrangement creates straight no-light-emitting areas that reduce illuminance evenness
Solution Approach 1:
The patent introduces curved wave-shaped groove portions between series-connected LED elements. This curvature disrupts the linear light emission pattern, scattering light laterally to fill in the dark areas that would otherwise exist between sequentially arranged elements. The series connection maintains total luminous flux while the curved grooves distribute it more evenly across the illuminated surface.
3Ease of manufacture
If larger intervals are provided between light emitting sections, then mounting and patterning is simplified, but dark portions become more visible on the illuminated surface
Solution Approach 1:
The patent forms curved wave-shaped groove portions that scatter light into the interval regions between light emitting sections. This curvature causes light to reflect and refract in multiple directions, effectively filling in the dark portions that would be visible with straight, wide intervals. The result is that larger, easier-to-manufacture intervals can be used without sacrificing illuminance evenness.
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 configuration decreases the unevenness of light emission and reduces dark portions on the illuminated surface, increasing the total light output from the LED array.
Implementation Method 1
forming a curved wave shape that reduces linear gaps and increases light scattering
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2D
AI summary
An LED array includes a substrate and a semiconductor structure layer provided on the substrate. The semiconductor structure layer includes a first semiconductor layer, an active layer formed on the first semiconductor layer, and a second semiconductor layer formed on the active layer. The semiconductor structure layer is partitioned into a plurality of light emitting sections by grooves formed in the semiconductor structure layer. Each groove is defined by two opposite side faces of adjacent light emitting sections. Each side face has a recessed and protruding configuration. In one embodiment, the protrusions and recesses of one side face of one light emitting section fit in respective recesses and protrusions of a corresponding side face of an adjacent light emitting section.