LED Lighting Module Diffusion Layers for Uniform Surface Light
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Solution Overview
Problem
Conventional lighting modules using LEDs as vehicle lamps face challenges in achieving uniform light distribution due to the small emitting angle of LEDs, leading to hot spots and reduced design flexibility, especially when trying to cover larger areas effectively.
Innovation Solution
A lighting module design featuring a substrate with multiple LEDs, a first resin layer, and a diffusion layer system that includes a diffusing agent and phosphor, where the diffusing agent and phosphor are strategically positioned to enhance light uniformity and wavelength conversion, allowing for improved light extraction efficiency and a flexible, slim form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LEDs are used as vehicle lamps, then power consumption is reduced, but light distribution uniformity deteriorates due to small emitting angle
Solution Approach 1:
A resin layer containing phosphor particles is introduced as an intermediary between the LED and the target surface. This resin layer receives light from the LED, converts part of it to different wavelengths through phosphor, and diffuses the light to achieve uniform illumination while maintaining LED energy efficiency
Solution Approach 2:
The patent changes the physical and chemical parameters of the resin layer, including phosphor particle concentration (1-10 wt%), particle size (1-50 μm), and resin thickness (0.1-5 mm), to optimize both light uniformity and wavelength conversion while preserving LED power consumption advantages
2Adaptability or versatility
If the light emitting area of LED lamp is increased to cover larger areas, then design freedom is improved, but the compact structure deteriorates
Solution Approach 1:
The patent transitions from a two-dimensional LED chip to a three-dimensional resin layer with phosphor particles, utilizing the thickness dimension (0.1-5 mm) to achieve light diffusion and wavelength conversion, thereby maintaining a compact form factor while expanding light coverage area
3Illumination intensity
If a diffusion layer is added to improve light uniformity, then light extraction efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single resin layer: light diffusion, wavelength conversion via phosphor, and protective encapsulation of the LED. This integration achieves light uniformity (90% or more) while avoiding the complexity of multiple separate layers or components
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 high light uniformity of 90% or more and reduces hot spots, providing a flexible and efficient surface light source with improved design freedom and reduced module thickness, suitable for various lighting applications including vehicle lamps.
Implementation Method 1
a first diffusion layer disposed on the first resin layer and diffusing light emitted from the first resin layer
Implementation Method 2
a second diffusion layer disposed on the first diffusion layer and diffusing light emitted from the first diffusion layer, wherein the first diffusion layer includes a diffusing agent and the second diffusion layer includes a phosphor
Data Source
AI summary
A lighting module according to an embodiment of the invention includes: a substrate; a plurality of light emitting devices disposed in N rows (N is an integer of 1 or more) on the substrate; a first resin layer covering the plurality of light emitting devices; a first diffusion layer disposed on the first resin layer and diffusing light emitted from the first resin layer; and a second diffusion layer disposed on the first diffusion layer and diffusing light emitted from the first diffusion layer, wherein the first diffusion layer includes a diffusing agent, and the second diffusion layer includes at least one of a phosphor and ink particles.