Light-emitting Module Irregular Wire Orientation Shadow Overlap
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Solution Overview
Problem
Luminance nonuniformity in light-emitting modules due to wire shadows, which occurs when wires connecting LED chips extend in the same direction, leading to overlapping shadows and reduced illumination intensity, especially at larger distances.
Innovation Solution
The light-emitting module features a mounting board with a conductor pattern where the wires connecting LED chips extend in irregular directions, reducing shadow overlap by positioning the wire edges outside the LED chips and allowing wires to extend from the edges of the light-emitting elements to the conductor pattern, thereby minimizing shadow areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires connecting LED chips extend in the same direction, then the wiring structure is simple and easy to manufacture, but wire shadows overlap causing luminance nonuniformity on the irradiation plane
Solution Approach 1:
The patent applies asymmetry by intentionally designing wires to extend in different directions from each LED chip rather than in uniform parallel directions. This asymmetric wire arrangement prevents shadow overlap on the irradiation plane, resolving the luminance uniformity issue while maintaining manufacturing feasibility through systematic directional variation.
Solution Approach 2:
The patent implements local quality by varying the extension direction of wires based on their specific location and the position of adjacent LEDs. Each wire's direction is optimized locally to avoid shadow overlap with neighboring wires, rather than applying a uniform direction pattern across the entire array, thus achieving luminance uniformity while keeping the overall structure manageable.
2Illumination intensity
If wires extend in irregular directions, then wire shadow overlap is reduced and luminance uniformity is improved, but the wiring structure becomes more complex
Solution Approach 1:
The patent applies dynamics by introducing controlled variability in wire extension directions rather than fixed uniform directions. The wire directions are dynamically adjusted based on local geometric constraints and shadow overlap considerations, creating an adaptive wiring pattern that achieves luminance uniformity without requiring complex manual routing for each wire.
Solution Approach 2:
The patent implements parameter changes by varying the extension direction parameter of wires across different locations in the LED array. Instead of maintaining a constant direction parameter for all wires, the system modifies this parameter locally to optimize shadow avoidance, achieving luminance uniformity while the changes follow systematic patterns that prevent excessive complexity.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A light-emitting module (2) includes a mounting board (1) with a conductor pattern and a plurality of light-emitting elements (15) mounted on the conductor pattern via wires (21). The extending direction of each of the wires (21) toward the conductor pattern is oriented irregularly when viewed perpendicularly to the mounting board (1). This can prevent the shadows of the wires (21) from overlapping, and thus can suppress the luminance nonuniformity.