Optical Plate Light-Blocking Pattern for Uniform LED Lamp Output
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Solution Overview
Problem
Existing lighting devices using light emitting diodes (LEDs) face challenges in expanding the light emitting area and achieving uniform light distribution due to the small emission angle of LEDs, which limits design freedom and increases the risk of hot spots and non-uniform light patterns.
Innovation Solution
An optical plate with a light-blocking pattern is designed, featuring different thicknesses in each region, including a first, second, and third light-blocking portion, arranged in specific non-overlapping configurations, to enhance pattern uniformity and light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a light emitting diode is used to increase light emitting area, then power consumption is reduced and design freedom is increased, but the small emission angle limits light distribution uniformity and creates hot spots
Solution Approach 1:
The patent applies local quality by creating a light-blocking member with spatially varying thickness and density. The light-blocking portion has different thicknesses in different regions (first, second, and third light-blocking portions with increasing thickness), and the inkjet printing process enables localized control of material density. This non-uniform structure selectively blocks light in specific areas to achieve uniform overall light distribution, directly addressing the hot spot problem caused by LED's narrow emission angle.
Solution Approach 2:
The patent utilizes parameter changes by varying the thickness and density parameters of the light-blocking material across different regions. The inkjet printing process allows precise control of material deposition parameters, creating a gradient structure where the light-blocking portion transitions from thinner to thicker regions. This parameter variation enables fine-tuned light attenuation to compensate for the LED's directional emission characteristics.
2Illumination intensity
If a light-blocking pattern is added to improve light uniformity, then hot spots are prevented, but the device structure becomes more complex
Solution Approach 1:
The patent merges the light-blocking function with the existing optical film structure. The light-blocking member is integrated into the optical assembly, combining light diffusion and light blocking functions in a single component system. The inkjet printing process further merges the pattern formation step into the manufacturing flow, eliminating the need for separate mask alignment and processing steps, thus reducing overall device complexity despite adding functional complexity.
Solution Approach 2:
The light-blocking member serves multiple functions: it blocks excessive light to prevent hot spots, shapes the light distribution pattern, and works synergistically with the diffuser layer. The inkjet-printed pattern provides both structural support and optical function. This multi-functionality reduces the need for additional separate components, offsetting the complexity increase from adding the light-blocking feature.
3Manufacturing precision
If inkjet printing is used to create light-blocking pattern with different thicknesses, then pattern uniformity is improved, but manufacturing process becomes more complex
Solution Approach 1:
The patent replaces traditional mechanical photomask alignment and exposure systems with inkjet printing technology. Instead of using physical masks and chemical development processes, the system directly deposits light-blocking material in precise patterns through digitally controlled inkjet nozzles. This substitution eliminates mechanical alignment errors and simplifies the manufacturing workflow, despite introducing new manufacturing equipment requirements.
Solution Approach 2:
The inkjet printing process enables precise control of material deposition parameters including droplet size, deposition speed, and layer thickness. By adjusting these parameters, the system achieves uniform patterns with controlled thickness variations. The digital control of printing parameters allows for easy reproduction of consistent patterns across multiple units, improving manufacturing precision while maintaining process simplicity through software control.
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 effectively prevents hot spots and improves light uniformity by controlling transmittance and brightness through adjustable density and thickness of light-blocking materials, enhancing the reliability of lighting devices and vehicle lamps.
Implementation Method 1
a light-blocking member disposed on an upper or lower surface of the optical film
Implementation Method 2
the light-blocking member includes a first light-blocking portion having a first pattern with a first thickness, a second light-blocking portion having a second pattern with a second thickness thicker than the first thickness
Data Source
Figure 1a
Figure 1b
Figure 2~3
AI summary
A lighting device disclosed in an embodiment of the invention may comprises a substrate; a plurality of light emitting devices on the substrate; a resin layer covering the light emitting devices on the substrate; an optical film on the resin layer; and a plurality of light-blocking members disposed on an upper or lower surface of the optical film and vertically overlapping each of the light emitting devices. The light-blocking members include a first light-blocking portion having a first pattern of a first thickness, a second light-blocking portion having a second pattern of a second thickness greater than the first thickness, and a third light-blocking portion having a third pattern of a third thickness greater than the second thickness, wherein the first, second, and third light-blocking portions vertically overlap with the upper surfaces of each light emitting devices. The first pattern of the first light-blocking portion has a size larger than other regions around the second and third light-blocking portions, the second pattern of the second light-blocking portion has a size larger than other regions on both sides of the third light-blocking portion, and the third pattern of the third light-blocking portion may have a single size.