Linear Light Source Recess Layout for Uniform Thin Edge Lighting
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Solution Overview
Problem
Existing methods for manufacturing linear light sources are not efficient in producing a thin type linear light source that can effectively utilize light emitting elements for edge type planar light sources, leading to issues with light distribution and luminance uniformity.
Innovation Solution
A method involving a base with recesses and reflective members is used to position and secure light sources, allowing for efficient light extraction and distribution, where the base is cut to form a continuous surface for light emission, incorporating a first and second reflective member to optimize light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional manufacturing methods are used for linear light sources, then the structure can support light emitting elements, but the resulting device is thick and has poor light distribution uniformity
Solution Approach 1:
The base is segmented into multiple recesses that individually hold light emitting elements, allowing precise positioning and optimized light extraction paths. This segmentation enables a thinner overall structure while maintaining uniform light distribution through controlled light extraction from each recess
Solution Approach 2:
The reflective members are strategically positioned at specific locations (bottom and side surfaces of recesses) to locally enhance light extraction efficiency. This localized reflection optimization allows reduction of overall device thickness while maintaining uniform luminance across the light source
2Illumination intensity
If light emitting elements are densely arranged to improve light output, then luminance increases, but manufacturing complexity and alignment difficulty increase
Solution Approach 1:
The recesses are pre-formed in the base structure before light emitting elements are installed. This preliminary structuring provides built-in positioning guides and alignment references, simplifying the subsequent assembly process and enabling dense arrangement of light emitting elements without increasing manufacturing complexity
Solution Approach 2:
The reflective members serve multiple functions: they reflect light to enhance extraction efficiency, provide structural support for the recesses, and facilitate alignment during assembly. This multi-functionality allows dense packing of light emitting elements while maintaining manageable manufacturing complexity
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 approach enables the creation of a thin type linear light source with improved light distribution and reduced luminance unevenness, enhancing the performance of edge type planar light sources by effectively utilizing light emitting elements.
Implementation Method 1
placing a first reflective member to cover the light sources and the first surface of the base so that the electrodes of the light sources are exposed from the first reflective member; placing a second reflective member on the second surface of the base
Data Source
AI summary
A method for manufacturing a linear light source includes: providing a base having a first surface defining recesses in an array in a first direction, and a second surface having a curved contour in a cross section orthogonal to the first direction and a straight contour in a cross section parallel to the first direction; providing light sources each having a top surface and a bottom surface including electrodes; placing the light sources at positions overlapping the recesses in a plan view with the top surface of the light source facing a bottom surface of the recess; placing a first reflective member to cover the light sources and the first surface so that the electrodes of the light sources are exposed; placing a second reflective member on the second surface; and cutting the base along the first direction to define a third surface continuous with the first and second surfaces.