Integrated LED Light Source Module with Tilted Reflection Surfaces
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Solution Overview
Problem
Conventional optical systems require complex light coupling processes between active light sources and light bars, leading to inefficient light utilization and manufacturing complications.
Innovation Solution
A light source module where the LED die, lead frame, and substrate are directly integrated within a light guide member, with a reflection film coating to optimize light emission and simplify manufacturing through co-injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the LED package and light bar are designed as independent components with separate light coupling, then the manufacturing process becomes complicated and light leakage cannot be fully eliminated, but integrating them directly simplifies the process and improves light utilization
Solution Approach 1:
The patent merges the LED package and light bar into a single integrated structure where the light guide member is directly formed within the packaging mold during LED package manufacturing. This eliminates the separate light coupling process between independent components, simplifies manufacturing, and prevents light leakage at interfaces while improving light utilization efficiency.
2Productivity
If the LED package and light bar are designed as independent components, then assembly flexibility is maintained, but the light coupling process becomes complicated and time-consuming
Solution Approach 1:
The light guide member is integrated into the LED package structure during the packaging manufacturing process itself, eliminating the need for separate assembly steps. This merging of functions into a single manufacturing process dramatically improves productivity while reducing the complexity of light coupling operations.
3Reliability
If separate light coupling is used between LED package and light bar, then component independence is maintained, but light leakage cannot be fully eliminated
Solution Approach 1:
By integrating the light guide member directly into the LED package structure during manufacturing, the patent eliminates interface gaps between separate components that cause light leakage. This merged structure provides reliable light containment while simplifying the overall assembly process.
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 integration simplifies the manufacturing process and enhances light utilization efficiency by eliminating the need for light coupling, while the reflection film and tilted surfaces control light emission direction and reduce leakage.
Implementation Method 1
the tilted surface is configured to reflect light emitted from the LED die toward the ejection surface
Implementation Method 2
a reflection film is coated on the surface of the light guide member for defining the ejection position of light of the light guide member
Data Source
AI summary
There is provided a light source module including an LED die and a light guide member. The light guide member is formed by injection molding to encapsulate the LED die. The light guide member is coated with a reflection film on a part of surface thereof and has at least one tilted surface opposite to the LED die.