LED Light Source Module With Reflective Lens for Thin Backlights
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Solution Overview
Problem
Current light source modules using semiconductor light emitting devices face challenges in maximizing light orientation angle and efficiency, particularly in high current/high power applications, where improving light distribution and reducing module thickness are essential.
Innovation Solution
A light source module design featuring a glass substrate with closely spaced light emitting diode chips, a multilayer reflective structure, and a lens with a high aspect ratio and acute contact angle, made from silicone with specific viscosity, to enhance light directivity and orientation angle without increasing module thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the light emitting diode chips are spaced closer together to increase light density, then the light distribution efficiency improves, but the manufacturing precision requirements increase due to the tight spacing tolerance
Solution Approach 1:
The patent divides the light source module into discrete LED chips mounted on a circuit board with standardized pitch. By segmenting the light source into multiple independent chips rather than a single large emitter, the system achieves better light distribution while using standard manufacturing tolerances for chip placement and spacing.
Solution Approach 2:
The patent optimizes the spacing parameter between LED chips to a specific range (7.5 mm or less) that balances light distribution efficiency with manufacturability. This parameter change allows close spacing for improved performance while remaining within standard mounting capabilities and tolerance ranges.
2Illumination intensity
If a multilayer reflective structure with alternating insulating layers is used to improve light reflection efficiency, then the light orientation angle increases, but the device complexity increases due to the multiple layered structure
Solution Approach 1:
The patent uses a multilayer reflective structure composed of alternating insulating layers with different refractive indices. This composite structure leverages optical interference effects to achieve high reflection efficiency and controlled light orientation angles. The specific combination of layers with contrasting optical properties creates constructive interference for desired wavelengths and angles.
Solution Approach 2:
The multilayer reflective structure utilizes optical interference to selectively reflect specific wavelengths and angles of light. By controlling the thickness and refractive index of each layer, the structure can be tuned to reflect particular portions of the spectrum, effectively using optical property changes to control light orientation.
3Ease of operation
If a lens with high aspect ratio and acute contact angle is used to enhance light directivity, then the light orientation improves, but the manufacturing precision requirements increase for the lens geometry
Solution Approach 1:
The patent employs a lens with a curved, spheroidal surface profile rather than flat or simple geometric shapes. This curvature is optimized to achieve the desired acute contact angle and high aspect ratio, which improve light directivity. The curved surface naturally focuses and directs light rays more effectively while being manufacturable using standard molding or injection techniques.
4Length of stationary object
If the lens thickness is reduced to achieve a thinner backlight module, then the module thickness decreases, but the light distribution efficiency may be compromised
Solution Approach 1:
The patent optimizes the lens thickness parameter to a specific range that maintains adequate light distribution functionality while achieving the goal of a thin backlight module. The thickness is carefully controlled to balance optical performance requirements with the overall thickness reduction objective, ensuring the lens remains effective at directing light even at reduced dimensions.
Solution Approach 2:
The use of a lens made from silicone material with specific optical properties allows for thinner design while maintaining performance. The material composition is selected to provide sufficient refractive index and optical clarity even at reduced thickness, compensating for the decreased path length through the lens material.
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 increases light orientation angle and directivity, allowing for a thinner backlight module with improved light distribution, addressing the need for enhanced efficiency in high current/high power applications.
Implementation Method 1
a multilayer reflective structure on the second surface of each of the plurality of light emitting diode chips, the multilayer reflective structure covering the respective second surface
Implementation Method 2
the multilayer reflective structure including a plurality of alternately stacked insulating layers having different refractive indices
Implementation Method 3
a lens respectively covering each of the plurality of light emitting diode chips and contacting the glass substrate, the lens having an acute contact angle with the upper surface of the glass substrate
Implementation Method 4
an optical sheet in front of the plurality of light emitting diode chips and including a quantum dot converting the blue light into white light
Data Source
AI summary
A light source module includes a circuit board, light emitting diode chips on an upper surface of the circuit board, the light emitting diode chips being spaced apart and each emitting blue light and having a first surface facing the upper surface of the circuit board, a second surface opposite the first surface, and first and second electrodes on the first surface, a first multilayer reflective structure on the second surface and including a plurality of alternately stacked insulating layers having different refractive indices, and a lens respectively covering each of the light emitting diode chips and contacting the upper surface of the circuit board at an acute contact angle, the lens having a thickness of 2.5 mm or less from the upper surface of the circuit board, and a contact region with the upper surface of the circuit board with a diameter of 1 mm to 3 mm.