LED Substrate Reflective Protrusions for Uniform Light Distribution
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Solution Overview
Problem
Conventional LED lighting devices for vehicles face challenges in achieving uniform light distribution due to the small emitting angle of LEDs, requiring increased light-emitting areas and complex designs, which can compromise economic efficiency and design flexibility.
Innovation Solution
A lighting device featuring metallic protrusions arranged on a substrate with a reflective portion and a resin layer, where the protrusions are designed to reflect light and enhance light intensity, allowing for a more efficient and flexible design without the need for a separate reflective film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a separate reflective film is added to improve light distribution, then light intensity is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines the reflective function with the substrate structure by forming metallic protrusions directly on the substrate surface. This integration eliminates the need for a separate reflective film, thereby improving light intensity through effective reflection while reducing device complexity and manufacturing difficulty.
Solution Approach 2:
The substrate serves multiple functions: it provides structural support and simultaneously incorporates reflective elements through the metallic protrusions. This multi-functionality allows the substrate to both hold the light source and reflect light to improve distribution, eliminating the need for additional dedicated reflective components.
2Illumination intensity
If a separate reflective film is added to improve light distribution, then light intensity is improved, but manufacturing process complexity increases
Solution Approach 1:
The reflective function is merged into the substrate fabrication process itself. The metallic protrusions are formed directly on the substrate using standard manufacturing techniques, combining the substrate creation and reflective element formation into a single integrated process, thereby simplifying manufacturing while improving light intensity.
3Illumination intensity
If the light-emitting area is increased to compensate for small LED emitting angle, then light distribution is improved, but design flexibility and economic efficiency are compromised
Solution Approach 1:
Instead of uniformly increasing the light-emitting area, the patent applies reflective elements (metallic protrusions) at specific locations on the substrate. These protrusions are strategically positioned to redirect light from the small LED emitting angle, achieving improved light distribution while maintaining a compact design and preserving design flexibility.
4Illumination intensity
If multiple layers and components are added to improve light distribution, then optical performance is improved, but module thickness increases
Solution Approach 1:
The reflective function is merged into the substrate structure itself through the metallic protrusions, eliminating the need for separate reflective layers or films. This integration maintains excellent optical performance for light distribution while avoiding the additional thickness that would result from adding separate reflective components.
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 intensity, adhesion, and optical reliability, simplifies manufacturing, and reduces module thickness, making it suitable for various applications including vehicle lamps and display devices.
Implementation Method 1
A lighting device featuring metallic protrusions arranged on a substrate with a reflective portion and a resin layer, where the protrusions are designed to reflect light and enhance light intensity
Data Source
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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.