Flexible OLED Housing with Segmented Cap for Form Retention
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Solution Overview
Problem
Existing methods for conforming and maintaining the form of flexible organic light-emitting diodes (OLEDs) in motor vehicle lighting and signaling devices are complex, costly, and risk damaging the OLEDs, as they require molding resin on the flexible OLEDs.
Innovation Solution
A light device comprising a flexible surface light source housed within a structure that includes a cap and a housing, allowing the OLED to be conformed and maintained without resin molding, enabling simple, rapid, and cost-effective form retention while preventing damage and external deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If resin molding is used to conform flexible OLEDs, then the form of flexible OLEDs can be maintained, but the manufacturing process becomes complex, lengthy and expensive, and the flexible OLEDs are at risk of damage
Solution Approach 1:
The housing is divided into two separate parts: a base housing and a cap. This segmentation allows the flexible OLED to be installed first in the base housing, then the cap is placed over it to provide conforming pressure and maintain the desired form. This eliminates the need for complex resin molding while achieving the same form-maintaining effect through a simpler, modular assembly process.
Solution Approach 2:
The flexible OLED is pre-formed or pre-bent to the desired shape before installation. The base housing is designed with a cavity that accommodates this pre-formed OLED, and the cap is then placed to maintain the shape. This preliminary preparation of the OLED form eliminates the need for post-installation molding or complex forming processes.
2Shape
If resin molding is used to conform flexible OLEDs, then the form of flexible OLEDs can be maintained, but the manufacturing time and cost increase significantly
Solution Approach 1:
By segmenting the housing into a base and a removable cap, the manufacturing process becomes a simple assembly operation rather than a time-consuming molding process. The cap can be quickly snap-fit or screwed onto the base housing, dramatically reducing manufacturing cycle time and increasing production throughput compared to resin molding methods.
Solution Approach 2:
The cap is designed as a simple, inexpensive plastic component that can be mass-produced through injection molding and quickly assembled. This replaces the expensive, time-consuming resin molding process with a cheap, rapid assembly operation that significantly improves manufacturing efficiency and reduces costs.
3Shape
If resin molding is used to conform flexible OLEDs, then the form of flexible OLEDs can be maintained, but the flexible OLEDs are at risk of damage during the process
Solution Approach 1:
The flexible OLED is pre-formed to the desired shape before installation in the housing. This preliminary preparation is done under controlled conditions where the OLED can be gently bent and formed without the risks associated with resin molding. Once installed in the base housing and secured with the cap, the pre-formed OLED maintains its shape without exposure to damaging molding processes.
Solution Approach 2:
The conforming function is extracted from the OLED itself and transferred to the housing structure. Instead of forcing the OLED to conform through resin molding, the base housing cavity and cap are designed to accommodate and maintain the desired shape of the pre-formed OLED, separating the conforming function from the OLED and applying it through the housing structure instead.
4Illumination intensity
If the housing and cap are made transparent to allow light passage, then light transmission is enabled, but protection against moisture and external factors may be compromised
Solution Approach 1:
Different parts of the housing have different optical properties: the base housing can be opaque for structural support and moisture protection, while the cap is made transparent or translucent specifically at the light-emitting areas to allow light passage. This local differentiation of material properties allows simultaneous achievement of light transmission and moisture protection in different zones of the same housing structure.
Solution Approach 2:
The housing utilizes composite construction with different materials or material treatments in different regions. The transparent cap material is selected to balance light transmission with moisture resistance, while the base housing uses opaque, moisture-resistant materials. This composite approach allows the structure to simultaneously provide both light transmission and environmental protection.
Data Source
AI summary
A light device for a motor vehicle lighting and/or signaling device includes a flexible surface light source a housing arranged to conform at least a part of the flexible surface light source according to a predetermined form a cap arranged to press said part of the flexible surface light source against the housing the housing and/or the cap being capable of allowing light emitted by the flexible surface light source to pass.