Lighting Module With Air Gap Light-Blocking Resin Layer
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Solution Overview
Problem
Conventional light emitting diodes (LEDs) used in lighting applications, such as vehicle lamps, have a limited light emitting area, leading to hot spots and reduced light uniformity due to their small emission angle, which affects the design freedom and efficiency of the lamp.
Innovation Solution
A lighting module is designed with a substrate, reflective member, and resin layer that includes light-blocking portions formed as air gaps, which are concave recesses on the resin layer, overlapping the LEDs to prevent hot spots and enhance light distribution, and a diffusion layer is applied using the adhesive force of the resin layer to improve light uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the light emitting area is increased to enhance design freedom and efficiency, then the light uniformity and hot spot prevention becomes more difficult to achieve
Solution Approach 1:
The resin layer is segmented into multiple functional regions: a light-blocking portion with specific geometric configuration (first, second, third, and fourth regions) and a light-transmitting portion. This segmentation allows the large light emitting area to be divided into zones that control light distribution, preventing hot spots while maintaining overall illumination uniformity across the expanded area.
Solution Approach 2:
Different portions of the resin layer are assigned different optical properties: the light-blocking portion (with areas defined by specific geometric regions) blocks light to prevent hot spots, while the light-transmitting portion allows light passage to maintain illumination. This local differentiation of optical quality enables simultaneous achievement of large light emitting area and uniform light distribution.
2Illumination intensity
If the light blocking portion is formed with specific geometric configuration to prevent hot spots, then the manufacturing complexity increases
Solution Approach 1:
The light-blocking function and geometric shape definition are merged into a single integrated structure within the resin layer. The light-blocking portion is formed by combining multiple regions (first region overlapping the light emitting device, second region extending in the first direction, third and fourth regions extending toward side surfaces) into one unified feature, simplifying manufacturing while achieving effective hot spot prevention.
3Loss of energy
If the reflective member is added to enhance light reflection efficiency, then the device complexity increases
Solution Approach 1:
The reflective member is designed to serve multiple functions simultaneously: it reflects light to improve extraction efficiency, provides a mounting surface for the resin layer, and contributes to the overall optical management of the light emitting device. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity while achieving enhanced light reflection efficiency.
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 improves the brightness and light uniformity of the surface light source by reducing hot spots and light loss, while also enhancing optical reliability and reflection efficiency, making it suitable for various lighting devices including vehicle lamps and liquid crystal display devices.
Implementation Method 1
a reflective member disposed on the substrate... the reflective member enhances light reflection efficiency
Implementation Method 2
the resin layer includes a light-blocking portion that is a recess region formed concave from an upper surface of the resin layer... preventing hot spots
Implementation Method 3
a diffusion layer disposed on the resin layer... improve light uniformity
Data Source
Figure 1
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AI summary
A lighting module disclosed in an embodiment of the invention may comprise: a substrate; a reflective portion disposed on the substrate; a plurality of light emitting devices disposed on the substrate; a resin layer disposed on the reflective portion and the light emitting devices; and a diffusion layer disposed on the resin layer. The resin layer includes a light-blocking portion that is a recessed area formed to be concave on the upper surface of the resin layer, and the light emitting devices emit light in a first direction, wherein the light-blocking portion may comprise: a first region overlapping the light emitting devices; a second region extending in the first direction from the first region; a third region extending from the second region in the direction of a first side of the substrate; and a fourth region extending from the second region in the direction of a second side of the substrate. The surface area of the second region may be larger than that of the third region or that of the fourth region, and the light-blocking portion may be formed as an air gap.