Flexible Light Guide With Cavities For Uniform LED Illumination
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Solution Overview
Problem
Existing light emitting devices with multiple LED units struggle to achieve homogeneous illumination over large areas, as they often result in uneven light distribution and are not easily scalable or flexible in design.
Innovation Solution
A light emitting device comprising a flexible circuit board with LED units arranged at spaced intervals, covered by a thin, flexible light guide with spacer elements that allow for total internal reflection and controlled light outcoupling, ensuring uniform light distribution across a large surface area, which can be bent to form curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple LED units are arranged on a board to illuminate large areas, then the illumination area is increased, but the light distribution becomes uneven and homogeneous illumination is difficult to achieve
Solution Approach 1:
A light guide plate is introduced as an intermediary component between the LED units and the illumination surface. The light guide receives light from multiple LED units and redistributes it uniformly across the entire surface through total internal reflection and controlled outcoupling, solving the uneven light distribution problem while maintaining large area illumination
Solution Approach 2:
The invention transitions from direct point-source LED illumination to a planar light distribution system. By using a light guide plate with controlled outcoupling structures, the light distribution is extended from discrete LED positions to a continuous two-dimensional surface, achieving uniform illumination across the entire area
2Stability of the object's composition
If rigid circuit boards and light guides are used, then structural stability is maintained, but flexibility and ability to conform to curved surfaces are lost
Solution Approach 1:
The invention replaces rigid circuit boards and light guides with flexible alternatives. The circuit board is made flexible to allow bending, and the light guide is implemented as a thin film that can conform to curved surfaces while maintaining its light-guiding functionality through total internal reflection
Solution Approach 2:
The system transitions from a static rigid structure to a dynamic flexible structure that can adapt its shape. The flexible components allow the illumination device to be configured on various surface geometries, including curved surfaces, while maintaining structural integrity and optical performance
3Illumination intensity
If complex structures with many components are used to achieve homogeneous illumination, then illumination uniformity is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The invention combines multiple functions into integrated components. The light guide plate simultaneously serves as the illumination surface, the light redistribution medium, and the structural element. The spacer elements are integrated into the assembly process, reducing the number of separate components and simplifying manufacturing while achieving homogeneous illumination
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 achieves high optical efficiency and flexible, scalable light emission with uniform illumination, allowing for desired light distribution patterns and conformability to various surface shapes, including curved surfaces, while maintaining a simple construction.
Implementation Method 1
The light guide is arranged to cover the LED units and the board top surface... in which light can propagate... A portion of the light may undergo total internal reflection (TIR) at boundary surfaces of the light guide
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5d
AI summary
A light emitting device 10 and a manufacturing method are disclosed. A board 16 comprises a board top surface 20. LED units 18 are arranged on the board top surface 20 at a distance from each other. A flat light guide 22 is arranged to cover the LED units 18 and the board top surface 20. The light guide 22 comprises a light guide bottom surface 24. Cavities 32 are formed in the light guide bottom surface 24. The LED units 18 are arranged to project into the cavities 32. Spacer elements 26 are arranged in between the board top surface 20 and the light guide bottom surface 24 to keep the board top surface 20 and the light guide bottom surface 24 at a distance d.