Optically Functional Multilayer Structure for Uniform Light Outcoupling
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Solution Overview
Problem
Integrated structures with optoelectronic light sources face challenges such as light bleed, leakage, and uneven illumination, which affect both functional and aesthetic aspects, and are complicated by the addition of optical features that can interfere with other components and increase manufacturing complexity.
Innovation Solution
A flexible, 3D-formable substrate film with electrical conductors and light sources is covered by an optically transmissive layer that redirects light through total internal reflection, using holes and outcoupling surfaces to control light distribution and eliminate the need for separate outcoupling features, thereby enhancing illumination uniformity and reducing structural and manufacturing complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light sources are integrated into the multilayer structure, then illumination functionality is achieved, but light bleed and leakage occur between different internal volumes
Solution Approach 1:
The patent divides the multilayer structure into distinct optical zones using optically transmissive layers with controlled light outcoupling areas. Each layer segments the light path to prevent bleed between internal volumes while maintaining illumination functionality in specific regions.
Solution Approach 2:
The optically transmissive layers are designed with spatially varying properties - certain areas allow light outcoupling while other areas block light transmission. This local differentiation of optical properties enables precise control over where light is emitted and where it is contained, preventing leakage without compromising illumination.
2Area of stationary object
If multiple light sources are used to illuminate large areas, then illumination coverage is improved, but illumination uniformity deteriorates with hot spots and leakage
Solution Approach 1:
The illumination system is segmented into multiple controlled outcoupling areas across different layers. Each light source illuminates a specific region, and the layered structure with controlled transmissivity ensures uniform light distribution without hot spots by preventing light concentration in any single area.
Solution Approach 2:
The patent transitions from planar 2D illumination to 3D volumetric illumination by stacking multiple optically transmissive layers at different heights. This dimensional approach allows light to couple out at multiple levels, distributing illumination more evenly across large areas and eliminating hot spots that occur with single-plane illumination.
3Manufacturing precision
If separate outcoupling features are added to control light distribution, then light control precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the outcoupling functionality directly into the optically transmissive layers themselves rather than adding separate outcoupling components. The layers are formed with integrated light outcoupling areas during the molding process, combining structural support and optical control functions into a single element, thereby reducing overall device complexity while maintaining precise light control.
Solution Approach 2:
The optically transmissive layers serve multiple functions simultaneously: they provide structural support for the multilayer assembly, guide light propagation, and control light outcoupling at specific areas. This multi-functionality eliminates the need for separate dedicated outcoupling features, reducing component count and manufacturing steps while achieving precise light distribution control.
4Manufacturing precision
If additional optical features are added to the structure, then optical performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple optical features - light guiding, light outcoupling, and structural support - into the optically transmissive layers that are formed using standard injection molding processes. By integrating these features during a single molding operation rather than adding them as separate post-processing steps, optical performance is achieved without proportionally increasing manufacturing complexity.
Solution Approach 2:
The patent optimizes optical performance by adjusting material parameters of the optically transmissive layers, such as refractive index and transmissivity, rather than adding complex optical components. These parameter changes are achieved through material selection and formulation, which can be implemented during standard manufacturing processes without requiring additional manufacturing steps or specialized equipment.
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 effectively controls light transmission and coupling, achieving uniform illumination and reducing the need for additional outcoupling features, leading to space, material, and weight savings while simplifying the manufacturing process and improving optical performance.
Implementation Method 1
the optically transmissive layer defines an outcoupling surface configured to redirect and reflect incident light emitted by one or more light sources
Data Source
AI summary
An integrated optically functional multilayer structure including a flexible, substrate film arranged with a circuit design including electrical conductors on a first side of the substrate film; at least one light source provided upon the first side of the substrate film and connected to the circuit design the at least one light source internally illuminates at least a portion of the structure for external perception; and an optically transmissive layer produced upon the first side of the substrate film and the at least one light source said optically transmissive layer at least partially covering the substrate film and embedding the at least one light source; wherein the substrate film defines holes therethrough and upon one or more of them the optically transmissive layer defines an outcoupling surface, configured to redirect and reflect, incident light emitted by light sources of the at least one light source.