Lighting Module Reflective Geometry for Hot Spot Reduction
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Solution Overview
Problem
Conventional lighting modules using light emitting diodes (LEDs) face challenges in providing a uniform surface light source due to limited light extraction efficiency and uneven light distribution, particularly in vehicle lamps where the emission angle of LEDs is narrow, leading to reduced luminous intensity and hot spots.
Innovation Solution
A lighting module design featuring a substrate with multiple LEDs, a resin layer, and a reflective member with varying curvatures and inclination angles around each LED, which enhances light extraction and distribution by reflecting light more efficiently across the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional lighting module uses standard reflective members around LEDs, then the structure is simple and easy to manufacture, but light extraction efficiency is limited and light distribution is uneven
Solution Approach 1:
The patent changes the geometric parameters of the reflective member, specifically setting the inclination angle α between 60-85 degrees and the height h between 0.5-1.5mm, to optimize light extraction efficiency while maintaining manufacturing feasibility
Solution Approach 2:
The reflective member is designed with a curved reflective surface rather than a flat surface, which improves light distribution uniformity and reduces hot spots by reflecting light from multiple angles across the light guide plate
2Reliability
If the reflective member has a larger inclination angle, then light extraction efficiency improves, but light distribution uniformity deteriorates due to hot spots
Solution Approach 1:
The patent optimizes the inclination angle α to be within 60-85 degrees, which balances light extraction efficiency and distribution uniformity by preventing excessive concentration of light in specific areas
Solution Approach 2:
The curved reflective surface distributes reflected light more evenly across the light guide plate by varying the reflection angles, reducing hot spots while maintaining high extraction efficiency
3Reliability
If the reflective member height is increased, then light reflection efficiency improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent specifies the reflective member height h to be between 0.5-1.5mm, which provides sufficient reflection efficiency while avoiding excessive height that would complicate manufacturing and assembly
4Use of energy by moving object
If conventional LEDs with narrow emission angles are used, then power consumption is reduced, but luminous intensity and light distribution are insufficient for vehicle lamp applications
Solution Approach 1:
The patent introduces a light guide plate as an intermediary between the LED and the light output surface, which redistributes the narrow-angle LED light across a larger area to achieve sufficient luminous intensity and uniform distribution
Solution Approach 2:
The curved reflective surface works with the light guide plate to scatter and redistribute light from the narrow-emission-angle LED, achieving broad and uniform illumination while maintaining low power consumption
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 proposed design improves light uniformity and reduces hot spots, increasing the luminous intensity and optical reliability of the lighting module, making it suitable for vehicle lamps and other display or lighting applications.
Implementation Method 1
a reflective member disposed around the plurality of light emitting devices... the reflective member includes a plurality of reflective units including a first reflective region and a second reflective region facing the first reflective region
Data Source
AI summary
A lighting module disclosed in an embodiment of the invention includes a substrate; a plurality of light emitting devices disposed on the substrate; a resin layer disposed on the plurality of light emitting devices; and a reflective member disposed around the plurality of light emitting devices. The reflective member includes a plurality of reflective units including a first reflective region and a second reflective region facing the first reflective region. At least one of the plurality of reflective units has a first angle between a straight line connecting an uppermost point of the first reflective region and a first point where the substrate and the first reflective region are in contact with each other and a tangent line of the substrate at the first point, and has a second angle between a straight line connecting an uppermost point of the second reflective region and a second point where the substrate and the second reflective region are in contact with each other and a tangent line of the substrate at the second point, and wherein at least one of the plurality of reflective units has the first angle and the second angle different from each other.