LED Module Reflective Portions Reduce Dark Areas

Solution Overview

Problem

Conventional light emitting diode (LED) modules for backlight applications face challenges in achieving uniform light distribution due to the generation of dark portions caused by manufacturing errors, which affect the luminance and color reproducibility.

Innovation Solution

The design includes a circuit board with reflective portions and connection portions, where light emitting devices are mounted, and lens units are disposed to cover the devices within the reflective portions' boundaries, with the reflective portions' width being greater than or equal to the lens units' diameter, and connection portions' width being smaller than the lens units' diameter, to enhance light reflectivity and reduce dark areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If lens units are disposed to cover light emitting devices within boundaries of reflective portions, then light uniformity is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvelight uniformityVSAvoidalignment precision

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating distinct zones with different functions: reflective portions with high reflectivity for light redirection, connection portions with lower reflectivity for electrical connection, and lens unit positions for light emission. Each zone is optimized for its specific function, with reflective portions having width greater than or equal to lens unit diameter to ensure complete light coverage and uniform distribution.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The circuit board is segmented into multiple functional regions: reflective portions, connection portions, and lens unit mounting positions. This segmentation allows each region to be optimized independently for its specific function while maintaining overall system performance and reducing manufacturing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If reflective portions have width greater than or equal to lens units' diameter, then light reflectivity is improved, but device complexity increases

Engineering Contradiction:

Improvelight reflectivityVSAvoidboard layout complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent optimizes the width parameter of reflective portions to be greater than or equal to the diameter of lens units. This parameter change ensures that all light emitted from lens units is captured and reflected effectively, minimizing light loss and maximizing luminous efficiency while maintaining a relatively simple board layout.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Instead of making connection portions wider to simplify manufacturing, the patent inverts the approach by making reflective portions sufficiently wide (greater than or equal to lens unit diameter) and connection portions narrower. This inversion prioritizes optical performance over manufacturing simplicity, achieving better light uniformity through optimized optical geometry.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If connection portions have width smaller than lens units' diameter, then fabrication cost is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvefabrication costVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating distinct zones with different functions: reflective portions with high reflectivity for light redirection, connection portions with lower reflectivity for electrical connection, and lens unit positions for light emission. Each zone is optimized for its specific function, with reflective portions having width greater than or equal to lens unit diameter to ensure complete light coverage and uniform distribution.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The circuit board is segmented into multiple functional regions: reflective portions, connection portions, and lens unit mounting positions. This segmentation allows each region to be optimized independently for its specific function while maintaining overall system performance and reducing manufacturing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

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 improves light uniformity by minimizing dark portions and increasing luminous efficiency, while also reducing fabrication costs by optimizing the board's layout and materials usage.

Implementation Method 1

a circuit board having a plurality of reflective portions arranged in one direction and connection portions connecting the plurality of reflective portions; light emitting devices mounted on the plurality of reflective portions

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS9759405B2Light emitting module and lighting device using the same

Publication Date: 2017.09.12 SAMSUNG ELECTRONICS CO LTD

AI summary

A light emitting module includes a circuit board having a plurality of reflective portions arranged in one direction and connection portions connecting the plurality of reflective portions, light emitting devices mounted on the plurality of reflective portions, and lens units disposed to cover the light emitting devices within boundaries of surfaces, of the plurality of reflective portions, on which the light emitting devices are mounted. A width of each of the connection portions in the other direction, perpendicular to the one direction thereof, is smaller than a diameter of each of the lens units, thus reducing a generation of a dark portion.