LED Resin Layer Structure for Wider Light Distribution
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Solution Overview
Problem
Existing light emitting diodes (LEDs) used in vehicle lamps have a limited emission angle, necessitating a solution to increase the light emitting area while maintaining design flexibility and efficiency.
Innovation Solution
A lighting device design featuring a substrate with light emitting devices arranged in rows and columns, a resin layer with alternating resin portions, and a reflective member to enhance light distribution and reduce light loss, utilizing materials like silicone and UV resin to prevent outgassing and improve adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional light emitting diodes are used in vehicle lamps, then power consumption is reduced, but the emission angle is limited and the light emitting area is insufficient
Solution Approach 1:
The light emitting device is divided into multiple LED chips arranged in an array configuration. Each LED chip acts as an independent light source, and collectively they provide a larger effective light emitting area while maintaining the advantages of individual LED technology. This segmentation allows the system to achieve broader illumination without requiring a single complex light source.
Solution Approach 2:
Multiple LED chips are combined into a single integrated light emitting device structure. The array of LED chips works together to provide enhanced light output and wider emission angle compared to a single LED, while sharing common support structures and electrical connections, thus achieving area expansion without proportional increase in overall device complexity.
2Illumination intensity
If the light emitting area is increased to improve light distribution, then illumination coverage is enhanced, but light loss increases
Solution Approach 1:
The resin layer is configured with alternating resin portions and air regions in a periodic pattern. This local variation in refractive index creates multiple internal reflection interfaces that redirect light paths, confining light within the light emitting device for longer paths and increasing extraction efficiency. The localized structural modifications prevent uniform light loss across the entire device.
Solution Approach 2:
The alternating resin portions and air regions create continuous light confinement and redirection throughout the light emitting device. Light that would otherwise escape is continuously reflected and redirected through the periodic structure, maintaining useful light action over extended paths and reducing overall light loss across the expanded light emitting area.
3Strength
If resin material is used to cover light emitting devices, then adhesion is improved, but outgassing occurs at high temperature
Solution Approach 1:
The light emitting device uses a composite structure combining resin portions and air regions. The resin material provides adhesion and encapsulation, while the integrated air regions create expansion space that accommodates thermal expansion and prevents outgassing issues. This composite approach allows the resin to perform its adhesive function without suffering from high-temperature outgassing problems.
Solution Approach 2:
The air regions are pre-configured within the resin layer structure before operation. These air regions act as cushioning spaces that accommodate thermal expansion and prevent pressure buildup that would cause outgassing. By providing this expansion space in advance, the design prevents the harmful outgassing effect before it occurs during high-temperature operation.
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 achieves a wider light distribution with reduced light loss, enhancing the luminance and optical reliability of the lighting device, suitable for various applications including vehicle lamps and display devices.
Implementation Method 1
a resin layer, in which resin portions and air regions alternately exist in a first direction
Implementation Method 2
designed to achieve a wider light distribution with reduced light loss
Implementation Method 3
A lighting device according to an embodiment includes a substrate, a light source, and a resin layer
Implementation Method 4
Light emitting device, such as light emitting diode (LED), have advantages such as low power consumption
Data Source
AI summary
A lighting device disclosed in an embodiment of the invention includes a substrate; a light source including a plurality of light emitting devices disposed on the substrate; a resin layer disposed on the substrate; and a first diffusion layer disposed on the resin layer, wherein the resin layer includes a first resin portion disposed on the light source, and a second resin portion adjacent to the first resin portion and disposed on the substrate. The upper surface of the first resin portion has an inclination and is spaced apart from the first diffusion layer, the second resin portion includes a material different from that of the first resin portion, and the second resin portion based on the upper surface of the substrate. The height of the upper surface may be greater than the lowermost height of the upper surface of the first resin portion.