Multilayer LED Substrate 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 to redistribute light, which increases complexity and costs in production.
Innovation Solution
A luminous means featuring a multilayer substrate with LEDs mounted on both sides, formed by folding a planar substrate sheet back on itself, eliminating the need for separate lenses and reducing production complexity by integrating light redirection into the substrate's design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If LEDs are mounted on a conventional single-sided substrate, then the structure is simple and easy to manufacture, but the light distribution is directional and cannot fill the rear space, requiring additional lenses to redistribute light
Solution Approach 1:
The invention transitions from a single-sided substrate to a multilayer substrate structure by folding the substrate back on itself, adding a spatial dimension that enables LED mounting on both sides. This creates multiple light emission directions without requiring additional optical components, thereby achieving more homogeneous light distribution while maintaining structural simplicity
Solution Approach 2:
The substrate is divided into multiple layers through the folding process, with each layer containing LEDs that emit light in different directions. This segmentation allows independent optimization of light emission for each layer while maintaining the overall simplicity of the substrate structure, resolving the contradiction between structural simplicity and light distribution homogeneity
2Illumination intensity
If additional lenses are added to redistribute light from LEDs, then homogeneous light distribution is achieved, but the device complexity and production costs increase
Solution Approach 1:
The invention merges the substrate structure with the light redistribution function by folding the substrate back on itself to form a multilayer configuration. This integration eliminates the need for separate lenses or optical components, achieving homogeneous light distribution through the substrate's geometric configuration alone, thereby reducing device complexity and production costs
Solution Approach 2:
The substrate itself performs the light redistribution function through its folded multilayer configuration, without requiring external optical components. The substrate's geometric structure inherently directs light in multiple directions, making the system self-sufficient and eliminating additional costs associated with lenses and optical assemblies
3Illumination intensity
If LEDs are mounted on both sides of the substrate, then light distribution in multiple directions is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The substrate is folded back on itself before LED mounting, pre-configuring the multilayer structure that enables bidirectional light emission. This preliminary geometric transformation simplifies the subsequent LED mounting process by providing ready-made mounting surfaces on both sides, thereby achieving multi-directional light distribution without proportionally increasing manufacturing complexity
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 multilayer substrate design achieves efficient light distribution in multiple directions without additional lenses, reducing production costs and complexity, while maintaining high light transmission through a transparent outer bulb.
Implementation Method 1
the at least two substrate layers are formed from a planar substrate sheet which is laid back on itself
Implementation Method 2
an outer bulb which is transmissive for the light emitted by the LEDs
Data Source
AI summary
The present disclosure relates to a luminous means having a cap and an outer bulb in which LEDs are arranged on a flat multilayer substrate which is constructed, at least in regions, from at least two substrate layers between two outside surfaces which are opposite one another, wherein the at least two substrate layers are formed from a flat substrate sheet which is laid back on itself, and wherein the LEDs are mounted on a side surface of the substrate sheet, which at least proportionally forms the two outside surfaces of the multilayer substrate in each case on account of the substrate sheet being laid back, in such a manner that at least one of the LEDs is mounted in each case on both of the two outside surfaces of the multilayer substrate.