LED Surface Light Module with Microstructures for Uniform Automotive Lighting
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Solution Overview
Problem
Current LED light emitting modules for automobiles fail to achieve uniform light emission and cannot support high brightness functions for applications like brake lamps and turn signal lamps, due to limitations in yield, brightness, and cost, especially when trying to achieve ultra-thin, curved surface shapes.
Innovation Solution
A surface light emitting module comprising a back plate, a light guide plate with concave/convex microstructures, and an optical film, where the LED light source and PCB are mounted on the light guide plate, and the optical film is used to enhance light distribution, comprising a prism film, diffusion film, and optionally a light filtering film, to achieve uniform and high-brightness light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional LED light emitting modules are used, then cost is reduced, but uniform light emission cannot be achieved
Solution Approach 1:
The light guide plate incorporates concave/convex microstructures at specific locations to locally modify light extraction properties. These microstructures are strategically positioned to enhance light emission uniformity across the surface without requiring expensive uniform LED arrays, thus achieving both cost-effectiveness and uniform light emission.
Solution Approach 2:
The patent introduces optical films (diffusion film, prism film) as intermediary elements between the LED light source and the external environment. These films mediate the light transmission process, scattering and redirecting light to achieve uniform surface emission while maintaining compatibility with standard LED modules, thereby resolving the contradiction between cost and uniformity.
2Ease of manufacture
If conventional LED light emitting modules are used, then cost is reduced, but high brightness function cannot be achieved
Solution Approach 1:
The patent modifies optical parameters by introducing concave/convex microstructures with specific geometric parameters (depth, diameter, spacing) on the light guide plate. These parameter changes optimize light extraction efficiency and directional control, enabling high brightness output from cost-effective LED modules by enhancing the optical pathway rather than increasing LED power consumption.
Solution Approach 2:
The invention adds a dimensional element by creating three-dimensional concave/convex microstructures on the light guide plate surface. This dimensional modification enables better light trapping and extraction in multiple directions, achieving high brightness function without increasing the fundamental LED array configuration or cost.
3Manufacturing precision
If OLED technology is used, then uniform surface light emission and ultra-thin shape are achieved, but cost increases and brightness is limited
Solution Approach 1:
The patent replicates the uniform light emission effect of expensive OLED technology using a different approach: combining conventional LED modules with a light guide plate featuring concave/convex microstructures and optical films. This 'copying' of the optical effect through alternative means achieves OLED-like uniformity at much lower cost, making the technology economically viable for mass production.
4Illumination intensity
If LED modules are designed for high brightness, then brake lamp and turn signal functions are achieved, but uniform light emission cannot be achieved
Solution Approach 1:
The light guide plate features locally optimized concave/convex microstructures positioned to address specific lighting requirements. Different regions of the light guide plate can have varying microstructure densities and geometries, enabling high brightness in signal areas while maintaining uniform emission across the entire surface, thus resolving the contradiction between brightness and uniformity for multi-functional automotive lighting.
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 enables uniform surface light emission, an ultra-thin structure, and a curved surface shape, allowing the module to be used in various automotive lighting functions such as tail lamps, brake lamps, and turn signal lamps with a spatial stereoscopic luminous effect, overcoming the limitations of existing technologies.
Implementation Method 1
The optical film is in the form of a prism film
Implementation Method 2
the diffusion film is disposed on a bottom layer of the prism film
Implementation Method 3
a plurality of concave/convex microstructures are disposed at intervals on the light guide plate
Implementation Method 4
a plurality of concave/convex microstructures are disposed at intervals on the light guide plate
Implementation Method 5
the back plate is used for specular reflection or white diffusion reflection
Data Source
AI summary
Provided are a surface light emitting module for an LED light source, a vehicle lamp using the same, and a method of assembling the same, so as to solve the technical problem that the existing LED light emitting module cannot achieve uniform lighting and cannot be used for the high brightness function as a brake lamp, a turn signal lamp, or the like. The surface light emitting module for an LED light source described in the present disclosure comprises: a back plate, a light guide plate, and an optical film disposed sequentially from back to front; and specifically, an LED light source and a PCB are disposed on a side of the light guide plate, and a plurality of concave/convex microstructures are disposed at intervals on the light guide plate.