Flexible Light Sheet with Sealed Bare-Die LEDs for Thermal Management
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Solution Overview
Problem
Conventional solid-state lighting systems face challenges with thermal management and light distribution, leading to increased size, cost, and glare issues, particularly when trying to conform to curved surfaces or achieve low-profile designs.
Innovation Solution
The development of flexible light sheets with bare-die light-emitting diodes and polymeric housings that seal and power the LEDs, allowing for efficient thermal management and customizable light distribution patterns while maintaining a compact and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-current operation is used to reduce LED count and cost, then productivity and cost are improved, but thermal management becomes more difficult and system volume increases
Solution Approach 1:
The patent combines the LED array with the diffuser into a single integrated light sheet structure. The LEDs are mounted directly on a flexible substrate that serves as both the mounting platform and the diffuser medium, eliminating the need for separate thermal management components and reducing overall system volume while maintaining high-current operation efficiency
Solution Approach 2:
The patent uses a flexible thin-film substrate to mount the LED array and provide thermal management. This thin-film approach replaces bulky traditional heat sinks and thermal management structures, enabling compact, low-volume lighting systems that can conform to curved surfaces while effectively managing heat from high-current LED operation
2Illumination intensity
If conventional LED systems are used to achieve high brightness, then illumination intensity is improved, but glare increases and light distribution control becomes more difficult
Solution Approach 1:
The patent merges the light source (LED array) with the light distribution control element (diffuser) into a single integrated light sheet. This integration allows the diffuser to be positioned immediately adjacent to each LED, providing effective glare control and uniform light distribution while maintaining high brightness output
Solution Approach 2:
The patent applies local quality by having each LED in the array paired with its own diffuser portion on the flexible substrate. This localized approach ensures that each light source's glare is controlled individually at its origin, while the overall array provides uniform, high-intensity illumination without excessive glare
3Temperature
If rigid thermal management structures are used to extract heat from LEDs, then temperature control is improved, but flexibility and adaptability to curved surfaces are reduced
Solution Approach 1:
The patent employs a flexible thin-film substrate that can conform to curved surfaces while providing thermal management functionality. This flexible structure replaces rigid heat sinks, enabling the lighting system to adapt to various surface geometries while maintaining effective heat extraction from the LED array
Solution Approach 2:
The patent uses composite material construction where the flexible substrate integrates multiple functions: mechanical support, thermal conduction for heat extraction, and optical diffusion. This multi-functional composite approach maintains temperature control effectiveness while providing the flexibility needed for curved surface applications
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 the creation of compact, reliable, and low-glare lighting systems that can be easily integrated into various environments, including harsh or curved surfaces, with improved thermal management and reduced material usage.
Implementation Method 1
array of light-emitting elements (e.g., bare-die light-emitting diodes)
Implementation Method 2
Top and or bottom housings, either or both of which may be polymeric, are utilized to seal at least portions of the light sheets and form sealed regions that may be water-resistant or waterproof
Data Source
AI summary
In accordance with certain embodiments, lighting systems include flexible light sheets and one or more sealed regions containing light-emitting elements, the sealed regions defined by seals between a top housing and a bottom housing and/or the light sheet.