LED Lighting Module with Concave-Convex Reflector for Uniform Distribution
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Solution Overview
Problem
Conventional LED lighting modules for vehicles face challenges in achieving uniform light distribution due to the small emitting angle of LEDs, leading to inadequate light coverage and efficiency.
Innovation Solution
A lighting module design incorporating a substrate with multiple LEDs and a reflector having a concave-convex reflective surface, where the reflective surface features convex portions and concave portions alternately disposed to redirect light emitted by the LEDs in an upward direction, enhancing light uniformity and reducing the need for a molding member to prevent light loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional LED is used as a vehicle lamp, then power consumption is reduced, but light coverage is insufficient due to small emitting angle
Solution Approach 1:
The patent divides a single large reflector into multiple smaller reflectors, each corresponding to a specific LED. This segmentation allows each reflector to independently redirect light from its associated LED, collectively achieving broader light coverage while maintaining the energy efficiency of individual LEDs.
Solution Approach 2:
The patent introduces a vertical dimension by positioning reflectors above the LEDs and redirecting light upward. This dimensional change transforms the traditional horizontal light emission pattern into a vertical redirection pattern, expanding the effective light coverage area while preserving LED energy efficiency.
2Reliability
If a molding member is added to prevent light loss, then optical reliability is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the molding member from the optical system by designing reflectors with precise reflective surfaces that naturally redirect light without requiring additional light-trapping structures. This removal simplifies the device while maintaining optical reliability through optimized reflector geometry.
Solution Approach 2:
The reflectors are designed to self redirect light effectively through their concave-convex surface geometry, eliminating the need for external molding members to prevent light loss. The reflective surfaces inherently perform the light management function that would otherwise require additional components.
3Illumination intensity
If a reflector with complex concave-convex surface is used, then light uniformity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The complex reflective surface is segmented into multiple discrete reflectors with simpler individual geometries. Each reflector handles a specific portion of the light field, which reduces the manufacturing precision required for each individual component while collectively achieving the desired light uniformity through the array configuration.
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 luminous intensity and light uniformity of the surface light source, enhances optical reliability, and eliminates the requirement for a molding member, thereby reducing optical losses and increasing the design flexibility of the lighting module.
Implementation Method 1
a reflector having a concave-convex reflective surface, where the reflective surface features convex portions and concave portions alternately disposed to redirect light emitted by the LEDs in an upward direction
Data Source
AI summary
A lighting module disclosed in an embodiment comprises: a plurality of light emitting devices on a substrate; and a reflector arranged in the direction of emission of light from each light emitting device on the substrate. The light emitting device has a light exit surface, and the reflector has a reflecting surface concave toward the substrate, at least a portion of the reflecting surface corresponding to the light exit surface of the light emitting device. The reflecting surface is arranged at a height that increases gradually in proportion to the interval from the light emitting device arranged in the light incident direction. The reflecting surface comprises a plurality of convex portions arranged in a first direction and first bridge portions that connect between the plurality of convex portions. The first bridge portions are arranged along the convex portions and are arranged to be lower than a straight line that connect high points of adjacent convex portions. The convex portions and the first bridge portions have the same length in a second direction, which is perpendicular to the first direction, and the area of the convex portions may be larger than the area of the first bridge portions.