Flexible Substrate LED Device with Folded Geometry for Multi-Directional Illumination
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Solution Overview
Problem
Existing light emitting devices with flexible substrates are limited in their ability to provide illumination in multiple directions, such as both sides or at 90 degrees, and suffer from structural instability over time due to the fixed positioning of LEDs on one side of the substrate.
Innovation Solution
A light emitting device with a flexible substrate featuring a fold combination of folds, such as mountain and valley folds, arranged in predetermined positions to maintain LED extension while rotating light output surfaces around the substrate's axis, allowing for additional illumination directions and increased stability through a rigid polymer encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If LEDs are arranged on the same side of the flexible substrate, then the structure is simple, but the illumination direction is limited and cannot provide multi-directional lighting
Solution Approach 1:
The patent applies dimensionality change by folding the flexible substrate along predetermined fold lines to create three-dimensional spatial arrangements. The substrate transitions from a two-dimensional flat configuration to a folded three-dimensional structure, enabling LEDs to face multiple directions (front, back, left, right sides) while maintaining a compact form factor. This resolves the contradiction by adding spatial dimensionality rather than increasing component count.
Solution Approach 2:
The patent utilizes the flexibility and deformability of the substrate to create dynamic spatial configurations. The substrate can be folded into various shapes (U-shape, zigzag, spiral) depending on the application requirements, allowing the illumination direction to be adjusted by changing the fold configuration rather than redesigning the entire structure.
2Reliability
If the flexible substrate is left without rigid encapsulation, then the device is easy to manufacture, but the position of LEDs becomes unstable over time due to play in the structure
Solution Approach 1:
The patent changes the physical state and mechanical properties of the substrate by applying rigid encapsulation. The flexible substrate transitions from a soft, deformable state to a rigid, stable configuration when enclosed in the rigid housing. This parameter change eliminates play and instability while maintaining manufacturing simplicity through a single encapsulation process.
Solution Approach 2:
The rigid encapsulation acts as a protective cushion that prevents future instability and position changes of the LEDs. By pre-encapsulating the folded substrate structure, the patent eliminates potential reliability issues before they can manifest during operation, ensuring long-term positional stability.
3Adaptability or versatility
If multiple folds are provided in the substrate, then additional illumination directions are achieved, but the structural complexity increases
Solution Approach 1:
The patent divides the flexible substrate into multiple segments separated by predetermined fold lines. Each segment can be independently positioned to create different spatial configurations. This segmentation allows the structure to achieve multiple illumination directions by simply adjusting which segments are folded and in what configuration, without increasing overall device complexity.
Data Source
AI summary
A light emitting device includes a flexible substrate, a plurality of LEDs arranged on the flexible substrate to emit light in a main direction perpendicular to both a longitudinal direction and a transversal direction of the flexible substrate a plurality of folds provided such that the flexible substrate is folded resulting in the main direction in which the light from at least one LED is rotated around the longitudinal axis or the transversal axis of the flexible substrate over a desired angle θ.