Flat Light Source Module Using Flexible Circuit Board
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Solution Overview
Problem
Conventional edge-light type LED plane lamps face challenges in achieving uniform light distribution and cost-effectiveness, particularly when designing non-square shapes like circular configurations, due to the rigidity of circuit boards and the need for complex light guide plates and reflectors.
Innovation Solution
A flat light source module comprising a flexible circuit board and light emitting device, where the circuit board curves along the light incident surface of a light guide plate, eliminating the need for a front cap and reflector, and incorporating light scattering microstructures and optical films for improved light distribution and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a non-square light guide plate (e.g., circular) is designed, then the effective light emitting region area increases, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies curvature by designing a circular light guide plate instead of a conventional square shape. The light guide plate has a circular light incident surface and a circular light exit surface, with curved side surfaces connecting them. This curved geometry maximizes the effective light emitting region area while maintaining manufacturing feasibility through standard circular molding processes.
2Stability of the object's composition
If rigid circuit boards are used, then the structural stability is maintained, but the adaptability to curved surfaces and non-square shapes is reduced
Solution Approach 1:
The patent employs a flexible circuit board that can be bent and conform to the curved surface of the circular light guide plate. The flexible circuit board carries LED light sources that are arranged along the curved perimeter, allowing the rigid LED components to be mounted on a flexible substrate that adapts to the non-square geometry while maintaining electrical connectivity and structural integrity.
3Illumination intensity
If a reflector and front cap are used to achieve circular light shape, then the desired light distribution is obtained, but the production cost and device complexity increase
Solution Approach 1:
The patent extracts and eliminates the reflector and front cap components from the conventional LED lamp structure. Instead of using these additional optical components to achieve circular light distribution, the invention relies on the circular geometry of the light guide plate itself and the strategic placement of LEDs on the flexible circuit board to directly produce the desired circular light pattern, thereby reducing component count and production cost.
Solution Approach 2:
The circular light guide plate serves multiple functions: it guides light from the LEDs, defines the circular light emitting boundary, and eliminates the need for separate reflector and front cap components. The flexible circuit board also serves dual purposes by providing both mechanical support for the LEDs and electrical connectivity, while its flexibility allows adaptation to the curved geometry without requiring additional shaping components.
4Reliability
If the light emitting surface is kept parallel to the light incident surface, then the coupling rate is maximized, but the ability to cover curved surfaces and eliminate dark regions is reduced
Solution Approach 1:
The patent transitions from a two-dimensional parallel arrangement to a three-dimensional curved arrangement. The flexible circuit board is bent into an arc that follows the curvature of the circular light guide plate's side surface. The LED light sources are positioned along this curved path, with their light emitting surfaces oriented to face the curved incident surface of the light guide plate, maintaining effective coupling while adapting to the non-planar geometry and eliminating dark corner regions.
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 design achieves better light uniformity, reduces production costs, and minimizes the overall size of the light source module by allowing the light emitting device to cover the entire curved surface, avoiding dark corners and enhancing light beam utilization.
Implementation Method 1
a light emitting device disposed on the flexible circuit board, wherein the light emitting device includes a light emitting surface facing the light incident curved surface
Implementation Method 2
The light guide plate includes a light incident surface, a light exit surface, and a bottom surface. The light exit surface is opposite to the bottom surface, wherein the light incident surface further includes a light incident curved surface, and the light incident curved surface is connected with the light exit surface and the bottom surface
Data Source
AI summary
A flat light source module including a light guide plate, a flexible circuit board and a light emitting device is provided. The light guide plate has a light incident surface, a light exit surface and a bottom surface opposite to the light exit surface, wherein the light incident surface further includes a light incident curved surface, and the light incident curved surface is connected with the light exit surface and the bottom surface. The flexible circuit board is disposed beside the light incident curved surface along the light incident curved surface of the light guide plate. The light emitting device is disposed on the flexible circuit board, and the light emitting device has a light emitting surface facing the light incident curved surface.