Flexible Light Emitting Device with Reflective Sheet and Adhesive
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Solution Overview
Problem
Existing flexible light emitting devices are costly and difficult to produce due to the use of insulating white ink and substrate holders, which limit their flexibility and increase production costs.
Innovation Solution
A bendable light emitting device is created by adhering flexible substrates with light emitting sections and a reflective layer to a reflective sheet with through holes, reducing the need for expensive insulating white ink and allowing for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating white ink is used to create reflective areas on flexible substrates, then electrical insulation is provided, but production cost increases and manufacturing complexity increases
Solution Approach 1:
The patent extracts the reflective function from the insulating white ink layer and places it on a separate reflective sheet. This allows the reflective sheet to provide reflection without the need for expensive insulating white ink, reducing material costs while maintaining electrical insulation through the adhesive layer and substrate structure.
Solution Approach 2:
The patent segments the device into distinct functional layers: flexible substrate with wiring pattern, reflective layer, insulating adhesive layer, and reflective sheet. This segmentation allows each layer to perform its specific function optimally - the reflective sheet provides reflection, the adhesive provides insulation and bonding, eliminating the need for expensive multi-functional insulating white ink.
2Stability of the object's composition
If substrate holders are used to secure LED substrates to metal sheet support, then structural stability is provided, but flexibility is reduced and production difficulty increases
Solution Approach 1:
The patent uses flexible substrates with printed wiring patterns instead of rigid LED substrates mounted on metal supports. The flexible substrate itself provides the structural base, eliminating the need for substrate holders and metal sheet supports. This maintains structural stability while preserving flexibility and simplifying the device construction.
3Reliability
If insulating white ink is used to provide reflective areas, then electrical insulation is achieved, but light extraction efficiency is limited
Solution Approach 1:
The patent extracts the reflective function from the insulating white ink and places it on a dedicated reflective sheet with high reflectivity. This separation allows the reflective sheet to maximize light extraction efficiency while the adhesive layer and substrate structure maintain electrical insulation, achieving both goals independently and optimally.
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 enables the production of a low-cost, flexible light emitting device with improved light extraction efficiency and reduced risk of electric shocks and static electricity, while maintaining insulating properties and flexibility.
Implementation Method 1
a reflective layer disposed at the peripheries of the light emitting sections directly on the wiring pattern or spaced apart from the wiring patterns in the stacking direction
Implementation Method 2
an insulating adhesive member adhering the flexible substrates to the reflective sheet in the regions where the reflective layer is not formed
Data Source
AI summary
A light emitting device includes a plurality of oblong flexible substrates, each flexible substrate comprising a sheet-shaped base body and a wiring pattern formed on one face of the base body, and each flexible substrate having a plurality of light emitting sections disposed thereon; a plurality of a reflective layers, each reflective layer being disposed at a periphery of a respective light emitting section above a respective flexible substrate; an insulating reflective sheet made of a light reflecting resin, the reflective sheet having a plurality of through holes located such that the light emitting sections and at least a portion of the reflective layers are exposed via the through holes; and a plurality of adhesive members, each adhesive member adhering a respective flexible substrate to the reflective sheet in regions where the reflective layer is not formed.