Flexible Light Guide Assembly for 3D Bendable Automotive Lighting
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Solution Overview
Problem
Current 3D LED architectures for automotive lighting applications are complex, costly, and prone to thermomechanical stress due to their system complexity, which restricts their flexibility and durability, especially when shaped and integrated into fixtures.
Innovation Solution
A flexible lighting device is developed using a bendable flexfoil with embedded light-emitting elements and an encapsulating material that allows the device to be formed into various shapes, reducing complexity and stress through a compact, ultra-thin design with a high integration of mini LEDs and a silicone-based encapsulating material that provides alignment and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple PCB substrate is used for arranging light-emitting elements, then the device structure is simple and easy to manufacture, but the device is restricted to an essentially flat shape and lacks flexibility
Solution Approach 1:
The patent replaces the rigid PCB substrate with a flexible foil substrate that can be bent and shaped in three dimensions. This flexible substrate maintains the electrical connection function while enabling the lighting device to conform to complex shapes and surfaces, directly resolving the contradiction between manufacturing simplicity and shape adaptability.
2Adaptability or versatility
If a complex 3D LED architecture is used to achieve various shapes, then the shape adaptability is improved, but the device complexity increases and thermomechanical stress occurs
Solution Approach 1:
The flexible foil substrate provides inherent shape adaptability without requiring complex 3D architectures. The simplicity of the flexible substrate design avoids the thermomechanical stress and manufacturing complexity associated with complex 3D LED structures, while still enabling various shapes and configurations.
3Stability of the object's composition
If light-emitting elements are arranged on a rigid substrate, then the structural stability is improved, but the device cannot be bent or shaped in three dimensions
Solution Approach 1:
The flexible foil substrate provides both structural stability for arranging light-emitting elements and the ability to be bent and shaped in three dimensions. The substrate maintains its integrity and electrical connections while allowing dimensional flexibility, resolving the contradiction between stability and adaptability.
4Adaptability or versatility
If multiple components are used to achieve flexibility and shape adaptability, then the adaptability is improved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The patent combines the substrate, electrical connections, and light-emitting element mounting into a single integrated flexible foil structure. This merging of functions into one component simplifies the manufacturing process and reduces costs compared to using multiple separate components to achieve the same flexibility and shape adaptability.
Data Source
AI summary
Lighting devices, methods of manufacturing a lighting device, automotive lighting systems including the lighting device are described. A lighting device includes at least one light guide with an elongated recess. Multiple light-emitting elements are embedded into the recess of the light guide, arranged on a flexfoil that is bendable in three different connections, and connected to one another to mimic a filament. At least one encapsulating material encapsulates, at least in part, the at least one light guide. The at least one encapsulating material includes at least one opening and at least one reference element for aligning the at least one light guide in relation to the encapsulating material so that the multiple light-emitting elements emit light exiting the opening. The at least one encapsulating aterial is flexible so that the lighting device is bendable in three different directions.