Surface Light-Emitting Unit with Support Members for Heat Release
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Solution Overview
Problem
Conventional surface light-emitting devices using point light sources suffer from luminance unevenness due to heat release issues and increased manufacturing costs, with protruding columnar members causing misalignment and reduced thermal conduction, and adhesive resin absorption leading to further luminance issues.
Innovation Solution
A surface light-emitting unit with support members of a predetermined height above a fixing substrate, where at least one support member is adhered via a white or transparent adhesive resin, creating a gap for heat release and preventing protrusion, thus ensuring even luminance and reduced optical absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If the light flux control member is completely covered with the light-emitting element, then the luminance becomes even, but the heat release property deteriorates
Solution Approach 1:
The light flux control member is divided into a light-emitting section and support members. The support members are separated from the light-emitting section to provide heat release paths while maintaining luminance uniformity through the light-emitting section's design.
Solution Approach 2:
The support members act as intermediaries that provide thermal conduction paths for heat release while maintaining the structural integrity and positioning of the light flux control member. They serve as a bridge between the light-emitting section and the fixing substrate.
2Temperature
If columnar members protrude from the fixing substrate, then heat release space is secured, but misalignment and reduced thermal conduction occur
Solution Approach 1:
Instead of having columnar members protrude upward from the fixing substrate, the support members are designed to extend downward toward the fixing substrate while being adhered via adhesive resin. This inverted approach eliminates protrusion issues while maintaining heat release functionality.
Solution Approach 2:
The adhesive resin is used as a temporary bonding medium that allows for precise alignment during assembly. The adhesive compensates for minor misalignments and provides sufficient bonding without requiring extremely precise mechanical positioning.
3Temperature
If adhesive resin is used to adhere support members, then heat release is enhanced, but optical absorption increases causing luminance unevenness
Solution Approach 1:
The adhesive resin is specifically selected to be white or transparent, which minimizes optical absorption in the visible spectrum. This color selection reduces the harmful optical effects while maintaining the thermal conduction benefits of the adhesive bonding.
4Manufacturing precision
If protruding portions are eliminated, then alignment and thermal conduction improve, but heat release space may be reduced
Solution Approach 1:
The support members extend in the vertical dimension toward the fixing substrate while being adhered at a specific height. This dimensional approach allows the support members to provide both alignment functionality and heat release pathways without protruding horizontally, thus eliminating misalignment issues while maintaining thermal management.
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 prevents luminance unevenness by maintaining consistent distance between light-emitting elements and the light-emitting surface, enhancing heat release and reducing manufacturing costs by eliminating the need for additional optical sheets or increased power supply.
Implementation Method 1
surface light-emitting devices employing solid state light-emitting elements such as LEDs (Light Emitting Diode) as point light-sources
Implementation Method 2
the end parts 105a of the columnar members 105 are fixed to the fixing substrate 104 in such a manner that the end parts 105a penetrate through-holes 104a in the fixing substrate 104 and are thermally adhered there
Implementation Method 3
light flux control members are provided at light-emitting surface sides of light-emitting elements (point light sources) in order to control angles of beams of light emitted from the light-emitting elements and smoothly broadening emitted light flux
Data Source
Figure 1~2
Figure 3
Figure 4(a)~4(b)
AI summary
A surface light-emitting unit of the present invention is an LED module (30) for emitting light from an LED chip (6) of a light-emitting element part (1) via a light flux control section (22) of a light flux control part (2), the light flux control section (22) being fixed by a plurality of columnar sections (21) above a fixing surface of a substrate (4) on which fixing surface the light-emitting element part (1)is fixed. This provides an appropriate gap between the light-emitting element part (1) and the light flux control section (22) for heat release.