Surface Light Source Module with Non-Uniform Phosphor Layer
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Solution Overview
Problem
Current surface light source modules for vehicles require high phosphor content to achieve uniform light output, leading to increased costs and reduced light-emitting efficiency, and attempts to reduce phosphor content by spacing LEDs further result in decreased light uniformity and increased costs.
Innovation Solution
A surface light source module design featuring a substrate with light-emitting elements, a first optical layer for light dispersion, and a second optical layer for wavelength conversion, where the distance ratios between these layers optimize light uniformity and reduce phosphor content, along with a third optical layer for external light blocking, allowing for improved aesthetics and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If phosphor content is increased to achieve uniform light output, then light uniformity is improved, but manufacturing cost increases and light-emitting efficiency decreases
Solution Approach 1:
The patent applies local quality by creating a non-uniform phosphor distribution pattern. Specifically, the phosphor layer has different thicknesses in different regions: a first thickness in a first region and a second thickness (greater than the first) in a second region. This localized variation in phosphor concentration allows different areas to contribute differently to light uniformity, achieving overall uniform illumination while using less total phosphor material, thereby reducing manufacturing cost.
Solution Approach 2:
The patent changes the parameter of phosphor layer thickness from a uniform value to a spatially varying value. By controlling the phosphor layer thickness to differ between regions (first thickness vs. second thickness), the patent optimizes the balance between light uniformity and phosphor usage efficiency, reducing the total phosphor content required while maintaining or improving light uniformity.
2Illumination intensity
If phosphor content is increased to achieve uniform light output, then light uniformity is improved, but light-emitting efficiency decreases
Solution Approach 1:
The patent applies local quality by creating a non-uniform phosphor distribution pattern. Specifically, the phosphor layer has different thicknesses in different regions: a first thickness in a first region and a second thickness (greater than the first) in a second region. This localized variation in phosphor concentration allows different areas to contribute differently to light uniformity, achieving overall uniform illumination while using less total phosphor material, thereby reducing manufacturing cost.
Solution Approach 2:
The patent changes the parameter of phosphor layer thickness from a uniform value to a spatially varying value. By controlling the phosphor layer thickness to differ between regions (first thickness vs. second thickness), the patent optimizes the balance between light uniformity and phosphor usage efficiency, reducing the total phosphor content required while maintaining or improving light uniformity.
3Ease of manufacture
If arrangement interval between light-emitting elements is increased to reduce cost, then number of light-emitting elements is reduced, but phosphor proportion must be further increased to improve light uniformity
Solution Approach 1:
The patent applies local quality by creating a non-uniform phosphor distribution pattern. Specifically, the phosphor layer has different thicknesses in different regions: a first thickness in a first region and a second thickness (greater than the first) in a second region. This localized variation in phosphor concentration allows different areas to contribute differently to light uniformity, achieving overall uniform illumination while using less total phosphor material, thereby reducing manufacturing cost.
Solution Approach 2:
The patent changes the parameter of phosphor layer thickness from a uniform value to a spatially varying value. By controlling the phosphor layer thickness to differ between regions (first thickness vs. second thickness), the patent optimizes the balance between light uniformity and phosphor usage efficiency, reducing the total phosphor content required while maintaining or improving light uniformity.
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 module achieves excellent light uniformity and reduced production costs by optimizing the layer distances and using a light-converting material, while maintaining high productivity and design flexibility.
Implementation Method 1
a first optical layer disposed on the light-emitting elements to cover the light-emitting elements and configured to disperse light emitted from the light-emitting elements
Implementation Method 2
a second optical layer disposed on the first optical layer and configured to absorb the light emitted from the light-emitting elements
Implementation Method 3
emit light of a different wavelength band from a wavelength of the absorbed light
Data Source
AI summary
A surface light source module includes a substrate, a plurality of light-emitting elements mounted on the substrate, a first optical layer disposed on the light-emitting elements to cover the light-emitting elements and configured to disperse light emitted from the light-emitting elements, and a second optical layer disposed on the first optical layer and configured to absorb the light emitted from the light-emitting elements and emit light of a different wavelength band from a wavelength of the absorbed light, wherein a distance from an upper surface of the first optical layer to an upper surface of the second optical layer has a value less than a distance from an upper surface of the substrate to the upper surface of the first optical layer.