Resin Light Guide Structure With Air Gap for Uniform Illumination
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Solution Overview
Problem
The integration of rod-shaped and plate-shaped portions in resin-molded articles using the same material results in unclear boundaries and inefficient light distribution, leading to non-uniform illumination, and increases manufacturing costs due to the need for different resin materials or light diffusing agents.
Innovation Solution
The integration of a light guide with an emitting surface and an incident surface separated by an air layer, supported by a common base material, allows for uniform light distribution and reduces manufacturing costs by using the same resin material for both components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rod-shaped portion and the plate-shaped portion are integrally molded from the same material, then manufacturing costs are reduced, but the boundary between portions becomes unclear and light distribution becomes non-uniform
Solution Approach 1:
An air layer is introduced as an intermediary between the rod-shaped light guide portion and the plate-shaped light emitting portion. This air layer acts as a boundary that maintains optical separation while allowing both portions to be integrally molded from the same resin material, thus resolving the contradiction between manufacturing cost reduction and light distribution uniformity
2Manufacturing precision
If different resin materials are used for the rod-shaped portion and plate-shaped portion, then light distribution uniformity is improved, but manufacturing costs increase
Solution Approach 1:
Both the rod-shaped light guide portion and the plate-shaped light emitting portion are molded from the same resin material, achieving homogeneity in material composition. The air layer boundary ensures proper optical separation, eliminating the need for different resin materials while maintaining light distribution uniformity and reducing manufacturing costs
3Manufacturing precision
If light diffusing material is added to the plate-shaped portion, then light distribution uniformity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The air layer serves as a boundary that naturally separates the light guide portion from the light emitting portion, eliminating the need for light diffusing materials in the plate-shaped portion. This simple structural solution maintains light distribution uniformity without adding material composition 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 configuration ensures efficient light propagation and uniform illumination over a longer distance while minimizing manufacturing costs by eliminating the need for different materials and diffusing agents.
Implementation Method 1
The emitting surface of the light guide and the incident surface of the light emitter are spaced apart from each other so as to face each other with an air layer interposed between the emitting surface and the incident surface
Data Source
AI summary
In a resin-molded article, a light guide on which light can be incident, a light emitter capable of emitting light using the light incident from the light guide, and a base material that supports the light guide and the light emitter are integrally formed. An emitting surface of the light guide and an incident surface of the light emitter are spaced apart from each other so as to face each other with an air layer interposed between the emitting surface and the incident surface.