Planar Light Source Resin Layering for Uniform Light Distribution
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Solution Overview
Problem
Existing methods for manufacturing planar light sources face challenges in forming a resin layer with a light-diffusing agent on a wiring substrate within a light guide plate's hole while avoiding resin formation on the light source's side surfaces.
Innovation Solution
A method involving a wiring substrate, a light guide plate with a first hole, and a light source with a light-emitting element and a light-transmitting member, where a resin material including a light-diffusing agent is injected and cured to form a resin layer on the substrate, with a protrusion on the light-transmitting member preventing resin adhesion to the light source's side surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If resin material is injected to form a resin layer on the wiring substrate inside the light guide plate's hole, then light distribution is enhanced and uneven luminance is reduced, but resin accumulates on the light source's side surfaces
Solution Approach 1:
The light-transmitting member is segmented into a body portion and a protrusion portion, where the protrusion serves as a dedicated structural element to prevent resin adhesion on the light source side surface while the body portion maintains light transmission function
Solution Approach 2:
The protrusion acts as an intermediary barrier between the resin material and the light source side surface, physically blocking the resin from adhering to the light source while allowing the resin to form a uniform layer on the wiring substrate
2Illumination intensity
If resin layer is formed to improve light distribution, then manufacturing complexity increases due to need to prevent resin adhesion on light source
Solution Approach 1:
The protrusion of the light-transmitting member simultaneously serves multiple functions: it prevents resin adhesion on the light source, maintains structural integrity of the light-transmitting member, and guides the resin flow to achieve uniform distribution on the wiring substrate
Solution Approach 2:
The protrusion creates a localized structural feature at the critical interface between resin and light source, providing differential properties (resin-release surface) only where needed, while the rest of the light-transmitting member maintains its light-transmission function
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
Enables easy formation of a resin layer with a light-diffusing agent on the wiring substrate inside the light guide plate's hole, enhancing light distribution and reducing uneven luminance while preventing resin accumulation on the light source's side surfaces.
Implementation Method 1
a first light-transmitting member covering the element side surface and the element upper surface
Implementation Method 2
a resin layer that includes a light-diffusing agent can be easily formed on the wiring substrate inside the first hole
Data Source
AI summary
A method for manufacturing a planar light source includes: preparing a structure body including a wiring substrate, a light guide plate including a first major surface, a second major surface, and an inner side surface defining a first hole with an opening on a first major surface side, and a light source arranged on the wiring substrate in the first hole; injecting a first resin material downward through the opening of the first hole, the first resin material including a light-diffusing agent; and curing the first resin material to form a first resin layer on a wiring substrate between the inner side surface of the first hole and a first side surface of a first light-transmitting member.