Multi-Layer LED Lighting Module for Uniform Wide-Angle Emission
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Solution Overview
Problem
Conventional LED lighting modules have a limited light emitting angle, which restricts their application in vehicle lighting and other applications requiring broader light distribution, and they often suffer from hot spots and reduced design flexibility due to thick module thickness.
Innovation Solution
A lighting module design featuring a substrate with multiple LED devices, a first resin layer, and multiple diffusion layers, including a phosphor and ink particles, to enhance light uniformity and distribution, with specific layer thicknesses and refractive indices to achieve a flexible, slim, and efficient surface light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple diffusion layers with phosphor and ink particles are added to improve light uniformity, then light distribution is improved, but device complexity increases
Solution Approach 1:
The patent divides the diffusion function into multiple separate layers: a first diffusion layer with phosphor particles for wavelength conversion and a second diffusion layer with ink particles for additional diffusion. This segmentation allows each layer to perform its specific function optimally, achieving superior light uniformity while maintaining manageable structural complexity through modular design.
Solution Approach 2:
The patent employs composite material structures by combining different diffusion mechanisms in separate layers - phosphor-based wavelength conversion in the first layer and ink-based diffusion in the second layer. This composite approach leverages the complementary properties of different materials to achieve enhanced light uniformity that cannot be obtained with a single diffusion mechanism.
2Ease of operation
If the module thickness is reduced to improve flexibility and design freedom, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent adopts a thin-film multi-layer structure where each diffusion layer is designed with optimized thin thickness to achieve the desired light uniformity while maintaining overall module flexibility. The use of thin resin layers combined with carefully controlled particle distributions enables the module to achieve both slim profile and operational flexibility.
Solution Approach 2:
The patent optimizes specific parameters including the thickness of each diffusion layer, the concentration and size distribution of phosphor and ink particles, and the refractive index matching between layers. By precisely controlling these parameters, the patent achieves uniform light distribution in thin modules while maintaining manufacturing feasibility through standardized parameter ranges.
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 improves light uniformity and distribution, reduces hot spots, and allows for thinner, more flexible modules with enhanced design freedom, suitable for various lighting applications including vehicle lamps and display devices.
Implementation Method 1
a first diffusion layer disposed on the first resin layer and including a phosphor
Implementation Method 2
a first diffusion layer disposed on the first resin layer and diffusing light emitted from the first resin layer
Implementation Method 3
a second diffusion layer disposed on the first diffusion layer and diffusing light emitted from the first diffusion layer
Data Source
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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.