Lightguide Plate Recessed Light Source Module
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Solution Overview
Problem
Existing light emitting modules face challenges in reducing thickness while maintaining optical performance, particularly due to the distance requirements between the mounting substrate and diffuser in conventional designs.
Innovation Solution
A light emitting module is manufactured using a lightguide plate with recessed portions and a light source attached to the bottom surface of these recessed areas, covered by a cover member to minimize gap width and enhance light propagation, allowing for thinner designs and improved alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional light source device with lens members and diffusers is used, then light emission function is achieved, but the thickness cannot be sufficiently reduced
Solution Approach 1:
The invention transitions from a conventional configuration where the light source is mounted on a substrate below the lightguide plate to a configuration where the light source is integrated into the lightguide plate itself. Specifically, the light emitting element is placed in a recessed portion formed directly on the lightguide plate, eliminating the need for a separate mounting substrate and reducing the overall thickness while maintaining light emission functionality.
Solution Approach 2:
The invention merges the mounting substrate function and the lightguide plate function into a single integrated structure. The lightguide plate incorporates both the light guiding function and the mounting function for the light emitting element through the recessed portion, thereby reducing the number of components and overall thickness.
2Length of moving object
If the distance between mounting substrate and diffuser is reduced, then thickness is reduced, but optical performance deteriorates
Solution Approach 1:
The invention applies local quality by creating a recessed portion with specific geometric characteristics (depth and lateral dimensions) at the precise location where the light emitting element is mounted. This localized structural modification optimizes light extraction and propagation in the immediate vicinity of the light source while maintaining overall module thickness reduction.
3Length of moving object
If components are closely arranged to reduce thickness, then manufacturing precision requirements increase
Solution Approach 1:
The invention applies preliminary action by pre-forming the recessed portion in the lightguide plate during the molding process before mounting the light emitting element. This pre-prepared structural feature provides automatic mechanical positioning and alignment guidance, significantly reducing the precision requirements for subsequent assembly operations.
Solution Approach 2:
The recessed portion acts as an intermediary structure that mediates between the light emitting element and the lightguide plate. It provides both mechanical support and optical coupling, facilitating precise alignment while accommodating manufacturing tolerances.
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 enables a thinner light emitting module with enhanced optical characteristics, reduced light leakage, and easier alignment, while maintaining effective light propagation to the extraction surface.
Implementation Method 1
a light emitting element that has a pair of electrodes on the same surface side
Implementation Method 2
arranging a cover member that buries a gap between the lateral surface of the recessed portion and the light source and covers the light source including the electrodes
Data Source
AI summary
A method for manufacturing a light emitting module including the steps of: preparing a light source including a light emitting element that has a pair of electrodes on the same surface side, and an encapsulation member that covers the light emitting element so as to expose a portion of a surface of the pair of electrodes; preparing a lightguide plate having a first primary surface to be a light emitting surface, and a second primary surface on an opposite side from the first primary surface, wherein the second primary surface has a recessed portion that has a bottom surface and at least one lateral surface; placing the light source on the bottom surface of the recessed portion with the electrodes facing up so as to be spaced apart from the lateral surface of the recessed portion; arranging a cover member that buries a gap between the lateral surface of the recessed portion and the light source and covers the light source including the electrodes; removing the cover member until the electrodes are exposed; and forming a metal film electrically connected to the light emitting elements.