Lighting Device Frame Member for Light Direction and Shielding

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Solution Overview

Problem

Existing lighting devices face challenges in efficiently directing lateral light emitted from light-emitting elements into upward light, and in effectively sealing and shielding these elements to prevent unnecessary phosphor excitation and light leakage.

Innovation Solution

A lighting device design featuring a substrate with a light-emitting element surrounded by a frame member made of white-colored resin, embedded within a light-transmitting resin that includes phosphors, and optionally a light-shielding member with graphite powder, where the frame member has sloping surfaces and openings to direct and shield light, and a method of manufacturing involving the embedding of the frame member and light-emitting element within a phosphor-containing resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a frame member is used to surround the light-emitting element, then light directionality is improved, but device complexity increases

Engineering Contradiction:

Improvelight directionalityVSAvoiddevice complexity

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The frame member is integrated directly into the molding process of the sealing resin, combining two previously separate components (frame and sealing resin) into a single molded structure. This reduces assembly steps and overall device complexity while maintaining the light-directional function of the frame member

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The frame member serves multiple functions simultaneously: it directs light upward, provides structural support for the light-emitting element, and acts as part of the sealing structure. This multi-functionality reduces the need for additional separate components, thereby simplifying the overall device

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Illumination intensity

If phosphor is included in the light-transmitting resin, then light conversion is improved, but unnecessary phosphor excitation occurs

Engineering Contradiction:

Improvelight conversionVSAvoidunnecessary phosphor excitation

Core Design Contradiction:

Illumination intensityVSLoss of energy

Solution Approach 1:

The patent extracts or removes the light-shielding member from the light path to prevent it from blocking or interfering with the light. By taking out this obstructing element, lateral light cannot reach the phosphor through unwanted paths, thus preventing unnecessary phosphor excitation while preserving the beneficial light conversion function

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potential harmful effect of lateral light (which could cause unwanted phosphor excitation) into a beneficial outcome by using the light-shielding member to redirect or block this lateral light, ensuring it does not reach the phosphor. This transforms what could be a loss of energy into a controlled light path that maintains efficiency

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the frame member and light-emitting element are embedded in light-transmitting resin, then sealing is improved, but manufacturing precision requirements increase

Engineering Contradiction:

ImprovesealingVSAvoidmanufacturing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The frame member, light-emitting element, and sealing structure are combined into a single molded component. This integration eliminates the need for separate sealing steps and reduces the cumulative tolerance stack-up that would occur with multiple assembly steps, thereby reducing manufacturing precision requirements while maintaining reliable sealing

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The molding process is segmented into distinct phases (such as injecting the sealing resin in stages or using a multi-cavity mold) that allow each component to be positioned and sealed independently with appropriate tolerances, reducing the overall manufacturing precision requirements while achieving reliable sealing

Inventive Principle:

Principle #1Segmentation

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 enhances light directivity and prevents unnecessary phosphor excitation by efficiently reflecting and shielding light, resulting in improved light emission and reduced phosphor excitation in adjacent openings.

Implementation Method 1

a frame member (3), surrounding the light-emitting element (2), wherein the frame member (3) includes a white-colored resin

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a light-transmitting resin (4) in which the light-emitting element (2) and the frame member (3) are embedded

Methodology Applied

Scientific EffectPhosphorescence: Phosphorescence

Data Source

PatentUS9232573B2Lighting device and method of manufacturing the same

Publication Date: 2016.01.05 CITIZEN ELECTRONICS CO LTD

AI summary

In a first aspect of the present inventive subject matter, a lighting device includes a substrate, a light-emitting element electrically mounted on the substrate, a frame member including a white-colored resin and surrounding the light-emitting element, and a light-transmitting resin in which the light-emitting element and the frame member are embedded. Also, it is suggested that the frame member further includes a light-shielding member entirely sealed by the white-colored resin.