UV-Curable Diffusing Layer for Uniform LED Illumination
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Solution Overview
Problem
Conventional lighting apparatuses for vehicles, such as mirror assemblies, often suffer from hot spots due to insufficient light diffusion, leading to objectionable illumination patterns when using LED light sources without diffusers, and require adhesives or mechanical structures to secure diffusers, which can introduce air gaps and reliability issues.
Innovation Solution
A diffusing layer comprising a resin material that cures in response to heat or ultraviolet light and a filler material with beaded structures is applied between the substrate and the light source, eliminating the need for adhesives and mechanical structures by directly bonding to the substrate, ensuring uniform light distribution and eliminating air gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional lighting apparatuses use LED light sources without diffusers, then the structure is simpler and requires fewer components, but hot spots occur due to insufficient light diffusion
Solution Approach 1:
The patent applies a composite diffusing layer comprising a resin material (such as UV-curable resin) mixed with filler particles (such as glass beads or titanium dioxide). This composite structure combines the optical scattering properties of the filler particles with the bonding and structural properties of the resin matrix, achieving uniform light diffusion while maintaining structural integrity and eliminating hot spots without requiring complex mechanical diffuser structures
Solution Approach 2:
The patent modifies the optical parameters of the lighting apparatus by introducing a diffusing layer with specific optical properties. The resin material is formulated with specific refractive indices and particle size distributions to control light scattering behavior, transforming the direct LED output into uniformly diffused light while maintaining the simplicity of the LED source itself
2Reliability
If adhesives or mechanical structures are used to secure diffusers, then the diffuser is held in place, but air gaps are introduced and reliability is reduced
Solution Approach 1:
The patent merges the diffusing function and the bonding function into a single integrated component. The resin-based diffusing layer serves dual purposes: it contains the filler particles to scatter light uniformly while simultaneously bonding the diffuser to the substrate or housing. This eliminates the need for separate adhesives or mechanical fasteners, removing air gaps and improving reliability without compromising structural support
Solution Approach 2:
The resin material acts as an intermediary substance that performs multiple functions simultaneously. It provides the optical diffusing properties needed for uniform illumination while also serving as the bonding medium that secures the diffuser in place. This intermediary material eliminates the interface between separate bonding components, preventing air gap formation and enhancing overall assembly reliability
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 provides uniform illumination by scattering light from the LED source, reducing the need for adhesives and mechanical structures, enhancing reliability and consistency across various environmental conditions.
Implementation Method 1
a resin material configured to cure in response to exposure to heat or ultraviolet light
Implementation Method 2
a filler material comprising a plurality of beaded structures configured to diffuse light from the light source
Data Source
AI summary
An illumination assembly configured to emit diffuse light through an indicator is disclosed. The assembly comprises a substrate having an applique disposed thereon. The applique forms an opening configured to transmit light through the substrate. The assembly further comprises a light source in connection with a circuit and configured to emit light through the shape. A diffusing layer is applied to a surface of the assembly between the circuit and the substrate. The diffusing layer comprises a resin material configured to cure in response to exposure to ultraviolet light or heat. The diffusing layer further comprises a filler material comprising a plurality of beaded structures configured to diffuse light from the light source.