Multilayer Light-Guiding Structure for Uniform Illumination Control
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Solution Overview
Problem
Existing optically functional integrated structures face challenges such as light bleed, leakage, and uneven illumination, along with increased complexity and power consumption, particularly in large area applications, due to the integration of light sources and optical features, which also pose design and manufacturing constraints.
Innovation Solution
A flexible, 3D-formable multilayer structure comprising a thermoplastic substrate film with additively printed electrical conductors, an optically transmissive plastic layer surrounding the light source, and a reflector design configured to control and direct light efficiently, reducing the number of light sources and enhancing illumination uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple light sources are integrated into large area structures, then illumination coverage is improved, but power consumption and structural complexity increase
Solution Approach 1:
The patent combines multiple light sources into a single integrated light guiding structure. The light guide layer distributes light from one or more light sources across a large area, eliminating the need for multiple separate light source assemblies and reducing structural complexity while maintaining broad illumination coverage.
Solution Approach 2:
The light guiding structure serves multiple functions simultaneously: it transports light from the light source, distributes it across the display area, and integrates with the display structure itself. This multi-functionality reduces the number of separate components needed and simplifies the overall device architecture.
2Illumination intensity
If light sources are integrated into multilayer structures, then illumination functionality is improved, but light bleed and leakage occur
Solution Approach 1:
The patent introduces a light guiding layer as an intermediary between the light source and the display elements. This layer controls and directs light propagation, preventing light from leaking or bleeding into areas where it should not appear, while still providing uniform illumination where needed.
Solution Approach 2:
The light guiding structure has spatially varying optical properties, with different regions designed to direct, diffuse, or block light as needed. This local optimization of light control prevents light bleed in critical areas while maintaining illumination functionality in display areas.
3Manufacturing precision
If optically transmissive layers surround light sources, then light control is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the light guiding layer, protective layer, and structural support into a single integrated multilayer component. This integration reduces the number of separate manufacturing steps and assembly operations required, while maintaining precise optical control through the layered structure.
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 solution effectively controls light incoupling and outcoupling, reduces power consumption and structural complexity, and achieves improved illumination uniformity and reduced size, while maintaining optical performance and hiding light sources until activated.
Implementation Method 1
a reflector design configured to control and direct light efficiently
Implementation Method 2
an optically transmissive plastic layer surrounding the light source
Data Source
AI summary
An integrated optically functional multilayer structure includes a flexible, substrate film arranged with a circuit design including at least a number of electrical conductors preferably additively printed on the substrate film; a light source provided upon a first side of the substrate film to internally illuminate at least portion of the structure for external perception; an optically transmissive plastic layer produced upon the first side of the substrate film, said plastic layer at least laterally surrounding, the light source, the substrate film at least having a similar or lower refractive index therewith; and a reflector design comprising at least one material layer, said reflector design being configured to reflect, the light emitted by the light source and incident upon the reflector design.