Deformable LED Array with Optical Out-Coupling Layer Stack
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Solution Overview
Problem
Current LED systems face challenges in achieving cost-effective integration, efficient heat management, and homogeneous light distribution with desired chromaticity and intensity, particularly in applications requiring flexible and complex form-factors, such as vehicle windshields, where light needs to be directed parallel to the road surface.
Innovation Solution
The use of a deformable backbone supporting LEDs connected via flexible wires, laminated between glass substrates with an optical out-coupling layer stack (OCLS) system, including an organo-metallic chelate hybrid material and scatterers, allows for conformable LED arrays that can be shaped to match specific applications, redirecting light efficiently and managing heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid PCB assemblies with mechanical dicing and robotic assembly are used, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses flexible PCB substrates that can be bent and conform to complex surfaces like windshields, replacing rigid mechanical assembly processes. The flexible nature allows direct integration without complex robotic manipulation and mechanical dicing, simplifying manufacturing while maintaining reliability through continuous flexible interconnections.
Solution Approach 2:
The patent employs composite structures combining flexible PCB materials with optical elements and adhesive layers integrated into a single laminated assembly. This composite approach eliminates multiple separate manufacturing steps and robotic operations, reducing process complexity while ensuring reliable integration of all components.
2Manufacturing precision
If LEDs are assembled on rigid PCBs with separate array formation steps, then manufacturing precision is improved, but adaptability to different applications and complex form-factors decreases
Solution Approach 1:
The flexible PCB substrate can be bent, shaped, and conformally attached to various surfaces including curved windshields. This flexibility provides adaptability to different application geometries while maintaining precise LED placement through controlled manufacturing processes for flexible circuits.
Solution Approach 2:
The flexible nature of the PCB allows the LED array to dynamically adapt to different installation geometries and application requirements. The substrate can be configured in various shapes and orientations during installation, enabling versatility across multiple applications while preserving manufacturing precision through standardized flexible circuit fabrication.
3Productivity
If sophisticated high-speed tools with robotic systems are used for LED assembly, then productivity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates multiple components (LEDs, flexible PCB, optical elements, adhesive layers) into a single laminated composite structure. This integration allows the entire assembly to be manufactured and installed as one unit, achieving high productivity through simplified single-step lamination processes rather than complex multi-step robotic assembly operations.
Solution Approach 2:
The flexible PCB substrate enables streamlined manufacturing where LEDs and other components can be directly mounted and laminated in a continuous process. The flexibility of the substrate allows for simplified handling and integration, improving productivity while avoiding the need for sophisticated robotic manipulation systems.
4Manufacturing precision
If conventional LED integration techniques are used, then manufacturing precision is improved, but heat management efficiency and light distribution homogeneity worsen
Solution Approach 1:
The flexible PCB substrate provides direct thermal pathways from LED junctions through the flexible circuit traces to the windshield glass and surrounding structures. The thin-film nature of the flexible PCB enables efficient heat conduction while maintaining close thermal contact with the mounting surface, improving heat dissipation compared to rigid PCB assemblies with thermal barriers.
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 solution enables improved light output directionality and efficiency, reducing heat buildup while maintaining flexibility and adaptability for various applications, including vehicle lighting, where light is directed parallel to the road surface with enhanced luminance and reduced angular distribution.
Implementation Method 1
an optical out-coupling layer stack (OCLS) system, including an organo-metallic chelate hybrid material and scatterers, allows for conformable LED arrays that can be shaped to match specific applications, redirecting light efficiently
Implementation Method 2
a matrix core including dispersed scatterers
Implementation Method 3
A deformable backbone supports a plurality of LED devices... managing the accumulation of heat during their operation
Data Source
AI summary
In certain example embodiments, light emitting diodes (LEDs) may be disposed on a deformable and flexible backbone sheet and chained together in an array, e.g., via flexible wiggle wires. Such flexible wiggle wires may also provide an electrical connection to an external power source. An optical out-coupling layer stack (OCLS) system may help serve as an index matching layer, heat sink, étendue conserver, etc. The backbone may be formed to a shape tailored to its ultimate application. Applications may include, for example, automotive (such as Center High Mounted Stop Lamp (CHMSL) applications), lighting, signage, and/or other applications. In an example CHMSL application, the deformable sheet with the LED array thereon has a step, sinusoidal, or other shape matched to the angle and/or curvature of the glass such that the LEDs produce light primarily in a direction parallel to a surface on which a vehicle is located.