Vehicle Lamp Reflection Structure for LED Light Extraction
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Solution Overview
Problem
The efficiency of light extraction from light-emitting elements in vehicle lighting devices is reduced due to light being absorbed by the substrate between the side surface of the light-emitting element and the inner wall of the frame part, and the presence of wiring wires complicates the reduction of this area.
Innovation Solution
A vehicle lighting device with a reflection part on the substrate between the side surface of the light-emitting element and the inner wall of the frame part, featuring a concave curved upper surface that protrudes toward the substrate, improves light extraction efficiency while allowing for a reduced substrate area and integration with the frame part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the distance between the side surface of the light-emitting element and the inner wall of the frame part is shortened to reduce substrate area, then light extraction efficiency is improved, but wiring wires prevent further area reduction
Solution Approach 1:
The harmful substrate area is extracted and replaced with a reflection part having a concave curved surface. This removes the light-absorbing substrate material from the critical region between the light-emitting element side surface and frame part inner wall, replacing it with a reflective structure that redirects light effectively while maintaining electrical connectivity through the wiring wire.
Solution Approach 2:
The reflection part is given a concave curved surface shape that protrudes toward the substrate. This curved geometry optimizes light reflection by redirecting light from the light-emitting element side surface at appropriate angles toward the front side, improving light extraction efficiency while accommodating the wiring wire within or around the curved structure.
2Loss of energy
If the substrate area between the light-emitting element and frame part is reduced, then light absorption by substrate is minimized, but wiring wires require space that conflicts with area reduction
Solution Approach 1:
The wiring wire, which originally occupied space and prevented area reduction, is integrated into the reflection part structure. The reflection part is designed to accommodate the wiring wire within its concave curved geometry, converting the wiring requirement from a constraint into part of the optical solution. This eliminates light absorption losses while managing wiring complexity through integrated design.
3Productivity
If a reflection part with concave curved surface is added, then light extraction efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The reflection part is merged with the frame part or substrate as an integrated structure rather than a separate component. By combining multiple functions (light reflection, structural support, and wiring accommodation) into a single integrated part with a concave curved surface, the design improves light extraction efficiency while simplifying manufacturing through reduced part count and integrated fabrication processes.
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 concave curved reflection part enhances light extraction efficiency, reduces thermal stress, and prevents wiring issues, enabling a more compact and durable vehicle lighting device design.
Implementation Method 1
Light emitted from the upper surface of the chip-shaped light-emitting element and incident on an inner wall of the frame part is reflected on the inner wall of the frame part and irradiated toward the front side of the vehicle lighting device
Data Source
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AI summary
An object of the disclosure is to provide a vehicle lighting device (1), a vehicle lamp (100), and a method for manufacturing a vehicle lighting device (1) capable of improving the efficiency of extracting light emitted from a light-emitting element (22). A vehicle lighting device (1) according to an embodiment includes: a socket (10); a substrate (21) provided on one end side of the socket (10); a light-emitting element (22) provided on the substrate (21); a frame part (23, 23a) provided on the substrate (21) and surrounding the light-emitting element (22); and a reflection part (26, 27, 28) provided on the substrate (21) and between a side surface of the light-emitting element (22) and an inner wall of the frame part (23, 23a). An upper surface of the reflection part (26, 27, 28) is a concave curved surface that protrudes toward the substrate (21) side.