LED Lamp Resin Layer Layout for Uniform Surface Light
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Solution Overview
Problem
Existing lighting devices using light emitting diodes (LEDs) face issues such as limited light emitting area, hot spots, non-uniform light distribution, visibility of the LED from the outside, and limited design freedom due to interference with other components like radars.
Innovation Solution
A lighting device design incorporating a substrate, reflective members, multiple resin layers, and wavelength conversion layers with varying heights and materials to enhance light distribution and aesthetics, allowing for uniform line and surface light sources, and emission of multiple wavelength bands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a light emitting diode is used as a vehicle lamp, then power consumption is reduced and lifespan is extended, but the light emitting area is limited and hot spots are formed
Solution Approach 1:
The patent divides the light emitting structure into multiple segments: the LED chip, reflective members surrounding it, and multiple resin layers with different refractive indices. This segmentation allows the light to be emitted in multiple directions and distributed more uniformly across a larger area, reducing hot spots while maintaining the energy efficiency of LED technology.
Solution Approach 2:
The patent transitions from a point-source light emission model to a distributed surface light source by adding vertical dimensionality through multiple resin layers of varying heights. The first resin layer has a first height and the second resin layer has a second height greater than the first height, creating a stepped structure that distributes light across both horizontal and vertical dimensions, effectively increasing the light emitting area.
2Use of energy by moving object
If a light emitting diode is used as a vehicle lamp, then energy efficiency is improved, but uniformity characteristic of the light emitting surface is deteriorated due to hot spots
Solution Approach 1:
The patent applies local quality by using resin layers with different refractive indices in different spatial zones. The first resin layer has a first refractive index and the second resin layer has a second refractive index different from the first, allowing each zone to optimize light distribution locally. This gradient approach prevents hot spots by gradually transitioning the light path, maintaining uniformity while preserving LED energy efficiency.
Solution Approach 2:
The patent changes the refractive index parameter across different resin layers to control light propagation. By using resin layers with different refractive indices and different heights, the light distribution pattern is modified to eliminate hot spots and achieve uniform illumination, while the LED itself continues to operate at high energy efficiency.
3Device complexity
If the light emitting diode is applied to a vehicle lamp, then the lamp structure is simplified, but the light emitting diode is visually recognized from the outside when the lamp is turned off, deteriorating esthetic and design freedom
Solution Approach 1:
The patent uses wavelength conversion layers that convert the blue or ultraviolet light from the LED into other wavelengths, enabling the lamp to display different colors in different states. When the lamp is off, the housing and wavelength conversion layers can be designed to appear as a uniform color or pattern, hiding the LED structure. When activated, the light emission provides functional visibility, thus maintaining aesthetics while simplifying the overall lamp structure.
4Adaptability or versatility
If the size of the logo or emblem is increased to implement various colors, then color variety is improved, but interference with radars located in the front or rear sides is caused
Solution Approach 1:
The patent achieves color variety by utilizing the vertical dimension through multiple resin layers and wavelength conversion layers rather than increasing the horizontal size of the logo or emblem. The different resin layers and wavelength conversion materials can emit different colors, providing versatility without expanding the footprint that would interfere with radar systems positioned in front or rear of the vehicle.
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 design minimizes light loss, provides uniform light emission, enhances design freedom, and prevents interference with other components, while allowing for varied light patterns and improved aesthetics.
Implementation Method 1
a wavelength conversion layer disposed on the resin layer... the second wavelength conversion layer disposed on the second resin layer
Implementation Method 2
a first reflective member disposed on the substrate... disposed on the outer surface of the resin layer
Data Source
AI summary
A lighting device according to an embodiment comprises a substrate, a light emitting device disposed on the substrate, a first reflective member disposed on the substrate, a resin layer disposed on the first reflective member, and a wavelength conversion layer disposed on the resin layer, wherein the resin layer includes a first resin layer, a second resin layer spaced apart from the first resin layer, and a third resin layer disposed between the first and second resin layers; the wavelength conversion layer includes a first wavelength conversion layer disposed on the first resin layer and a second wavelength conversion layer disposed on the second resin layer, and the height of the second resin layer is different from the height of the first resin layer; and the light emitting device may be disposed in a region vertically overlap the second and third resin layers but vertically overlap the first layer.