Flexible Substrate Joining Without Connectors

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Solution Overview

Problem

Conventional light emitting devices require connectors to join substrates, leading to increased manufacturing costs and reduced flexibility in substrate arrangement due to the need for more connectors and space.

Innovation Solution

A substrate joining structure that connects a flexible substrate to another substrate without using joining components like connectors, utilizing an electrically conductive joining member across the wiring patterns to secure the connection, thereby eliminating the need for connectors and improving substrate arrangement flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If connectors are used for joining substrates to each other, then the substrates can be connected reliably, but the manufacturing cost increases and the area required for disposing the connectors increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidnumber of connectors

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the electrical connection function and the mechanical support function into a single integrated structure. The electrically conductive joining member serves both as an electrical conductor and as a structural element that provides mechanical support, eliminating the need for separate connectors and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrically conductive joining member performs multiple functions simultaneously: it provides electrical connection between substrates, offers mechanical support, and enables flexible arrangement of substrates. This multi-functionality replaces the need for dedicated connectors, reducing both cost and complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If connectors are used for joining substrates to each other, then the substrates can be connected securely, but the manufacturing cost increases due to the number of connectors

Engineering Contradiction:

Improvejoining strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent combines the electrical connection function and the mechanical support function into a single integrated structure. The electrically conductive joining member serves both as an electrical conductor and as a structural element that provides mechanical support, eliminating the need for separate connectors and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrically conductive joining member is designed to provide both electrical and mechanical functions through its own structure, without requiring additional supporting components. This self-sufficiency reduces the number of parts needed and simplifies the manufacturing process.

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If connectors are used for joining substrates to each other, then the substrates can be connected stably, but the area required for disposing the connectors increases, decreasing the degree of freedom in arrangement

Engineering Contradiction:

Improvesubstrate connection stabilityVSAvoidarea for connectors

Core Design Contradiction:

Stability of the object's compositionVSArea of stationary object

Solution Approach 1:

The patent employs flexible substrates that can be arranged in various configurations without requiring rigid connector structures. The flexible nature of the substrates allows for compact arrangements and flexible positioning, reducing the area required for connections while maintaining stability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes the flexible substrate to create three-dimensional arrangements and overlapping configurations, allowing substrates to be connected in space rather than requiring planar connector placements. This dimensional flexibility reduces the area required for connections while maintaining stable joining.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 reduces manufacturing costs by eliminating the need for connectors and enhances the flexibility in arranging substrates, while ensuring a strong and reliable connection between the substrates.

Implementation Method 1

an electrically conductive joining member is disposed at positions across the first wiring pattern and the second wiring pattern while covering a portion of the first wiring pattern

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11271145B2Light emitting device

Publication Date: 2022.03.08 NICHIA CORP

AI summary

A light emitting device includes: a substrate including: a flexible base member, a first wiring pattern located on the upper surface of the base member, the first wiring pattern including: a first component-side conductive portion, and a second component-side conductive portion, and a plurality of reinforcing lands located on the upper surface of the base member, the plurality of reinforcing lands including: a first reinforcing land, and a second reinforcing land; and a plurality of light emitting elements mounted on the substrate, each light emitting element being electrically connected to the first component-side conductive portion and the second component-side conductive portion.