Vehicle Lighting Module Resin Structure for Uniform Light Extraction

The patent divides a single LED into multiple separate LED chips arranged on a circuit board. Each LED chip emits light in a specific direction, and together they create a larger effective light emitting area while maintaining low power consumption. The segmentation allows for flexible arrangement patterns to achieve desired light distribution.

The patent transitions from a single-point light source to a distributed array of multiple LED chips across a two-dimensional plane. This dimensional expansion increases the light emitting area without proportionally increasing power consumption, as multiple chips can share the total power load while providing broader illumination coverage.

The patent introduces a translucent or transparent resin layer as an intermediary between the LED chips and the external environment. This resin layer serves multiple functions: it optically couples the LED chips, extracts light efficiently from multiple angles, and provides a uniform diffusing medium that eliminates hot spots. The resin may contain wavelength conversion particles to adjust the color temperature and improve overall light extraction efficiency.

The patent uses a homogeneous resin material that uniformly fills the space between and around the LED chips. This homogeneous medium ensures consistent light extraction from all LED chips, creates uniform light distribution across the entire emitting area, and eliminates variations in light intensity that would otherwise occur at chip boundaries or interfaces.

The patent merges multiple functions into the single resin layer: optical coupling, light extraction, wavelength conversion, and uniform diffusion. By combining these functions into one integrated component rather than separate elements, the design achieves improved light distribution uniformity without proportionally increasing structural complexity. The resin layer becomes a multi-functional element that simplifies the overall assembly.

The patent employs a composite material consisting of the resin base material combined with wavelength conversion particles (such as phosphors). This composite structure enables the resin to perform both optical coupling and wavelength conversion functions simultaneously. The composite material approach improves light extraction and distribution uniformity while adding minimal structural complexity, as the particles are dispersed within the existing resin matrix rather than requiring separate conversion layers.