LED Lighting Module With Reflective Protrusions for Wide Light Distribution
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Solution Overview
Problem
Conventional LED lighting devices for vehicles face challenges in achieving wide light distribution due to the small emitting angle of LEDs, requiring increased light-emitting areas and complex designs, which can be costly and limit design flexibility.
Innovation Solution
A lighting device with a substrate featuring a metal layer, protrusions made of metallic materials arranged in the exit direction of the LED, and a resin layer to enhance light reflection and distribution, eliminating the need for a separate reflective film and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED is used as vehicle lamp to reduce power consumption, then energy efficiency is improved, but light-emitting area is reduced due to small emitting angle
Solution Approach 1:
The patent introduces a three-dimensional protrusion structure with reflective surfaces on the substrate, transforming the traditional two-dimensional flat substrate into a multi-dimensional light-guiding structure. This dimensional change allows light to be redirected and distributed across a wider area without increasing the planar footprint of the LED component itself.
Solution Approach 2:
The protrusion structure acts as an intermediary element between the LED light source and the surrounding environment. It receives light from the LED and redistributes it through its reflective surfaces, effectively mediating the light distribution process to achieve wider coverage while maintaining the compact LED form factor.
2Illumination intensity
If separate reflective film is added to improve light distribution, then light intensity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the substrate and the reflective function into a single integrated structure. The protrusions are formed directly on the substrate, eliminating the need for separate reflective films or additional components. This consolidation reduces device complexity while maintaining effective light distribution through the geometric design of the protrusions.
Solution Approach 2:
The substrate structure serves multiple functions simultaneously: it provides mechanical support and performs light reflection and distribution. The protrusions are self-sufficient in their light-guiding function, requiring no additional reflective coatings or separate optical components, thereby simplifying the overall device architecture.
3Area of stationary object
If multiple components are used to achieve wide light distribution, then light coverage is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The substrate is segmented into multiple protrusion elements with different orientations and shapes. Each protrusion segment independently guides and reflects light in specific directions, collectively achieving wide-area coverage. This segmentation allows for modular manufacturing and simplifies the production process compared to using multiple separate optical components.
Solution Approach 2:
The protrusion structure serves multiple functions within a single component: structural support, light reflection, light distribution, and directional control. This multi-functionality eliminates the need for multiple specialized components, thereby simplifying manufacturing processes and reducing production costs while achieving comprehensive light coverage.
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 improves light intensity and distribution, reduces module thickness, and enhances adhesion and optical reliability, allowing for more flexible and efficient vehicle lighting designs.
Implementation Method 1
protrusions made of metallic materials arranged in the exit direction of the LED, and a resin layer to enhance light reflection and distribution
Data Source
AI summary
The lighting device disclosed in the embodiment of the invention includes a substrate including a metal layer; a plurality of light sources arranged in a first direction on the substrate; a plurality of protrusions having a length in the first direction on the metal layer; and a resin layer disposed on the plurality of light sources and the plurality of protrusions, wherein the metal layer includes a first metal layer electrically connected to the light source and a second metal layer coupled to the plurality of protrusions, and the first metal layer and the second metal layer are separated from each other, and the plurality of protrusions may be disposed to be spaced apart from each other in a second direction perpendicular to the first direction.