Segmented Light Guide Module for Uniform Illumination
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Solution Overview
Problem
Existing light bar modules with a single-piece injection-molded lens face challenges in achieving uniform light distribution and eliminating hotspots due to insufficient mechanism space, leading to light loss and uncontrollable refraction.
Innovation Solution
The light bar module is designed with an outer and inner light guide member, split into multiple pieces, allowing for reduced mechanism thickness and size, enabling effective light diffusion by continuous refraction or reflection at their interface, and allowing for the addition of diffusing agents only where needed to maintain brightness and reduce space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-piece injection-molded lens is used, then the lens structure is simple and manufacturing is easy, but the mechanism space is insufficient leading to hotspot generation and uncontrollable light refraction
Solution Approach 1:
The lens is divided into multiple separate pieces (first lens piece, second lens piece, etc.) instead of using a single-piece structure. Each lens piece has specific optical functions and can be independently manufactured with precise control over light refraction and diffusion, eliminating hotspots while maintaining manufacturing feasibility.
2Manufacturing precision
If the lens dimensions are increased (vertical distance and horizontal distance greater than 6.0 mm) to eliminate hotspots, then light diffusion improves, but the mechanism space requirement increases
Solution Approach 1:
By segmenting the lens into multiple pieces with optimized individual dimensions, the patent achieves effective light diffusion and hotspot elimination without requiring each piece to have large dimensions. The segmented structure allows light to be diffused through multiple interfaces and surfaces, maintaining uniformity in compact spaces.
Solution Approach 2:
Different lens pieces have different optical properties and functions tailored to their specific positions and roles in the light bar module. This allows optimized light control in each local region, achieving overall uniform light distribution without requiring uniform large dimensions throughout the entire lens structure.
3Manufacturing precision
If diffusing agents or diffusing powder are added to assist light diffusion, then hotspot elimination improves, but the manufacturing complexity and material processing difficulty increase
Solution Approach 1:
The patent divides the light diffusion function across multiple lens pieces with specific geometric structures rather than relying on diffusing agents mixed into a single-piece lens. This segmentation approach achieves effective light diffusion through optical design alone, simplifying the manufacturing process by eliminating the need for material mixing and reducing 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 design effectively avoids hotspot generation, reduces light loss, and maintains uniform light distribution, even in constrained spaces, while simplifying the injection molding process and reducing bending deformation of optical plastic materials.
Implementation Method 1
achieving uniform light distribution and eliminating hotspots due to insufficient mechanism space, leading to light loss and uncontrollable refraction
Implementation Method 2
enabling effective light diffusion by continuous refraction or reflection at their interface
Data Source
AI summary
A light bar module includes an outer light guide member, an inner light guide member, and a circuit board. The outer light guide member is provided with a first accommodating space and a light-emitting surface on two sides respectively. The inner light guide member is provided with a second accommodating space, and the inner light guide member is accommodated in the first accommodating space. The circuit board is provided with a plurality of light-emitting elements, and each of the light-emitting elements is accommodated in the second accommodating space and is configured to emit light from the light-emitting surface.