Flexible Optically Functional Multilayers with Tilted Light Outcoupling
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Solution Overview
Problem
Existing integrated structures face challenges with undesired light bleed, light leakage, transmission losses, and difficulty in controlling illumination uniformity and spatial control of light, especially in large areas, which can lead to increased size, weight, and complexity, as well as compatibility issues with other features.
Innovation Solution
A flexible, 3D-formable substrate film with integrated electrical conductors and optically transmissive layers that redirect and reflect light using total internal reflection, eliminating the need for separate outcoupling features and allowing for controlled light coupling and scattering through a tilted outcoupling surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate outcoupling features are used to control light transmission, then illumination uniformity is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the outcoupling surface functionality directly into the substrate film by tilting specific regions of the substrate surface. This integration eliminates the need for separate outcoupling components while achieving controlled light transmission and illumination uniformity through the tilted substrate regions that redirect light paths.
Solution Approach 2:
The substrate film serves multiple functions simultaneously: it provides structural support, electrical conductivity through integrated conductors, and optical light redirecting through tilted regions. This multi-functionality reduces overall device complexity by consolidating what would traditionally require separate components into a single integrated substrate.
2Illumination intensity
If multiple light sources are added to improve illumination coverage, then illumination intensity is improved, but light leakage and structural size increase
Solution Approach 1:
Instead of adding more light sources horizontally, the patent utilizes the third dimension by tilting the substrate film surfaces. This tilting creates angular light paths that redirect light toward desired output regions, improving illumination coverage without adding additional light source components that would cause leakage.
3Manufacturing precision
If light guiding elements are added to control light paths, then light transmission control is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The light guiding function is merged directly into the substrate film structure through tilted regions. These tilted areas naturally redirect light paths through refraction and total internal reflection, eliminating the need for separate light guiding elements and simplifying manufacturing while maintaining precise light transmission control.
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 provides efficient control over light transmission and illumination uniformity, reduces structure size and weight, simplifies manufacturing, and enhances compatibility with other features by integrating light redirecting and scattering capabilities within the substrate.
Implementation Method 1
an optically transmissive layer, optionally of plastic or thermoplastic material, such as polycarbonate, produced, preferably molded, upon the first side of the substrate film and the at least one light source, said optically transmissive layer at least partially covering the substrate film and embedding the at least one light source
Data Source
AI summary
An integrated optically functional multilayer structure including a flexible, substrate film arranged with a circuit design including electrical conductors on a first side of the substrate film; at least one light source provided upon the first side of the substrate film and connected to the circuit design the at least one light source internally illuminates at least a portion of the structure for external perception; and an optically transmissive layer-produced upon the first side of the substrate film and the at least one light source said optically transmissive layer at least partially covering the substrate film and embedding the at least one light source; wherein the substrate film defines holes therethrough and upon one or more of them the optically transmissive layer defines an outcoupling surface, configured to redirect and reflect, incident light emitted by light sources of the at least one light source.