LED Substrate with Folded Inclined Surfaces for Homogeneous Light Distribution
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Solution Overview
Problem
Conventional luminous means with LEDs face challenges in achieving homogeneous light distribution due to directional light emission, requiring additional components like lenses for redistribution, which increases complexity and assembly errors in mass production.
Innovation Solution
A luminous means with a flat substrate that has LEDs mounted on inclined part surfaces, allowing for directional adjustability of light emission without additional components, reducing assembly complexity and errors by integrating light directionality into the substrate design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LEDs are used to replace filament bulbs, then energy efficiency and lifespan are improved, but homogeneous light distribution deteriorates due to directional light emission
Solution Approach 1:
The substrate is folded along fold lines to create three-dimensional inclined part surfaces from an initially flat two-dimensional structure. This dimensional transformation allows LEDs mounted on these inclined surfaces to emit light in multiple directions, achieving homogeneous light distribution without requiring additional optical components.
Solution Approach 2:
Different part surfaces of the substrate are folded to different angles relative to the base plane, creating locally optimized light emission directions. Each inclined part surface is tailored to redirect light from LEDs mounted on it toward specific spatial regions, collectively achieving uniform omnidirectional illumination.
2Illumination intensity
If lenses are added to redistribute light from LEDs, then homogeneous light distribution is improved, but device complexity and assembly errors increase
Solution Approach 1:
The light redistribution function traditionally performed by separate lens components is merged into the substrate structure itself. The substrate serves dual purposes: as the mounting platform for LEDs and as the light redirecting element through its folded three-dimensional geometry, thereby eliminating the need for additional optical components.
Solution Approach 2:
The light redistribution function is extracted from separate optical components (lenses) and integrated directly into the substrate structure. By folding the substrate to create inclined surfaces, the patent achieves light redirection without requiring externally attached optical elements, simplifying the overall device architecture.
3Adaptability or versatility
If multiple separate components are used for light redistribution, then light distribution control is improved, but manufacturing precision requirements and production costs increase
Solution Approach 1:
The substrate is divided into multiple foldable part surfaces separated by fold lines, with each part surface independently angled to control light emission in specific directions. LEDs mounted on different part surfaces contribute to different spatial zones, enabling precise light distribution control through the segmented modular structure.
Solution Approach 2:
The substrate is pre-folded along predetermined fold lines during manufacturing to create the three-dimensional inclined part surfaces before LED assembly. This preliminary structuring establishes the light redirection geometry in advance, simplifying subsequent assembly operations and reducing precision requirements during final assembly.
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 approach enables flexible light distribution adaptation with reduced parts and assembly errors, improving manufacturing efficiency and reducing inventory costs by integrating light directionality into the substrate, achieving homogeneous light distribution without the need for additional lenses or complex assemblies.
Implementation Method 1
at least two part surfaces of the substrate are folded out relative to the remainder of the substrate in each case about a bridge region via which the respective part surface is connected to the remainder of the substrate
Data Source
AI summary
A luminous means is disclosed, the luminous means having LEDs on a substrate, an outer bulb in which the substrate having the LEDs is arranged, and a cap, wherein at least two partial surfaces of the substrate are folded out with respect to the remaining substrate around a bridge area in each case, via which the particular partial surface is connected to the remaining substrate, and are thus set obliquely with respect to the remaining substrate which is flat per se, wherein, for each side surface of the remaining substrate, which side surfaces are opposite one another with respect to a thickness direction of the remaining substrate, at least one partial surface is folded out in each case, and wherein at least one of the LEDs is arranged on each of the partial surfaces.