Bendable Substrate Illuminating Device for Flexible FA Inspection
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Solution Overview
Problem
Existing ring-shaped illuminating devices for image processing in FA fields face challenges in accommodating various object specifications while maintaining cost-effectiveness and reliability, as they often require complex configurations that increase costs and limit flexibility in illumination field variations and work distances.
Innovation Solution
A substrate with a flexible first portion and harder, bendable second portions, each mounted with light emitting elements, allows for flexible arrangement and connection of light emitting elements to accommodate different specifications, enabling a range of illumination configurations through a manufacturing method that cuts and shapes the substrate to specific dimensions and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex configuration is used to accommodate various object specifications, then the adaptability improves, but the device complexity and cost increase
Solution Approach 1:
The substrate is designed to be bendable, allowing the light emitting elements to be arranged in different configurations (flat, curved, circular, etc.) to match various object shapes and illumination requirements. This dynamic flexibility enables a single substrate design to adapt to multiple applications without requiring complex fixed configurations for each case.
Solution Approach 2:
The invention creates a universal substrate design that can serve multiple functions by bending it into different shapes and arranging light emitting elements in various patterns. The same substrate can be used for flat illuminations, curved surfaces, circular patterns, and other configurations, eliminating the need for multiple specialized designs.
2Adaptability or versatility
If a complex configuration is used to accommodate various object specifications, then the adaptability improves, but the manufacturing cost increases
Solution Approach 1:
The bendable substrate allows the same manufactured component to be deployed at different work distances by adjusting its curvature and shape. The substrate can be bent to position light emitting elements at various distances from the object, enabling a single manufacturing process to produce components suitable for multiple work distance requirements.
Solution Approach 2:
By changing the bending radius and curvature of the substrate, the work distance and illumination characteristics can be adjusted without requiring different manufacturing processes. The physical parameter of substrate curvature becomes a variable that controls illumination behavior, allowing cost-effective adaptation to different specifications.
3Manufacturing precision
If light emitting elements are mounted on a rigid substrate, then the mounting precision improves, but the flexibility and adaptability decrease
Solution Approach 1:
The substrate maintains rigidity at the local level where light emitting elements are mounted, ensuring precise positioning during assembly. However, the overall substrate structure remains bendable, allowing the entire array to be deformed into different shapes (curved, circular, folded) to achieve various illumination patterns and adapt to different application geometries.
Solution Approach 2:
The substrate is designed with segmented flexibility - rigid zones for mounting light emitting elements with precision, and flexible zones that allow bending and shaping. This segmentation enables simultaneous achievement of manufacturing precision at the component level and adaptability at the system level.
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 approach enables the production of multiple illuminating devices with varying specifications at reduced costs, enhancing flexibility and reliability by allowing for precise control over illumination patterns and distances without mechanical stress on the light emitting elements.
Implementation Method 1
an illuminating device using a light emitting element (LED: Light Emitting Diode)
Data Source
AI summary
To provide a method for manufacturing a plurality of types of illuminating devices having different specifications while reducing cost. A substrate includes a common flexible portion and a plurality of units bendable with respect to the common portion, where the common portion includes a pad that is extended in the horizontal direction in the plane of the drawing and that is arranged for every predefined interval. In the present manufacturing method, a substrate piece is created by cutting the substrate mounted with the light emitting element in a first direction, the common portion in the substrate piece is formed according to the illuminating device to be manufactured, the relative position of the individual portion with respect to the formed common portion is respectively positioned, and the wiring for supplying power to the pad in the substrate piece is formed.