Multilayer Optically Functional Structure for Large Area Illumination
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Solution Overview
Problem
Existing optically functional integrated structures face challenges such as light bleed, leakage, and uneven illumination, particularly in large area applications, where achieving uniformity and dynamic control of light is difficult, and the integration of optical features often complicates manufacturing and design due to compatibility issues and increased complexity.
Innovation Solution
A flexible, 3D-formable multilayer structure with top-emitting light sources and an optically transmissive plastic layer, combined with a reflector design to control and optimize light emission, using materials like polycarbonate and PMMA, which allows for efficient light management and reduced component count, enabling 'hidden until lit' functionality and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple light sources are used to illuminate large areas, then illumination coverage is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The illumination area is divided into multiple zones, each served by a dedicated light source positioned at specific locations. This segmentation allows large area coverage while maintaining manageable complexity through modular light source placement rather than requiring a single complex illumination system.
Solution Approach 2:
Light sources are positioned in three-dimensional space at optimized locations rather than merely arranged in a planar pattern. By utilizing vertical and depth dimensions, the system achieves broader illumination coverage with fewer light sources, reducing overall device complexity.
2Illumination intensity
If light sources are positioned close to the illuminated area, then illumination intensity is improved, but light bleed and leakage increase
Solution Approach 1:
Optical elements such as light guides, diffusers, or reflective surfaces are introduced as intermediaries between the light sources and the illuminated area. These intermediaries channel and direct light efficiently while preventing direct light bleed and leakage, maintaining high intensity without the harmful effects of uncontrolled light spread.
Solution Approach 2:
Different regions of the illumination system are optimized with specific optical properties - light sources are positioned at locations where local geometric constraints and optical element characteristics naturally prevent light bleed while maintaining intensity. Each zone has tailored optical characteristics suited to its specific illumination requirements.
3Adaptability or versatility
If optical features are integrated into existing structures, then functionality is improved, but manufacturing complexity increases
Solution Approach 1:
Optical features such as light guides, diffusers, and reflective elements are combined with structural components of the device housing or substrate. This merging allows optical functionality to be integrated without requiring separate complex manufacturing processes, as the optical elements are formed as part of the overall structure through techniques like injection molding or 3D printing.
Solution Approach 2:
Certain structural elements are designed to serve multiple functions - providing both mechanical support and optical functionality simultaneously. For example, a housing component may act as both a structural element and a light guide, reducing the need for additional dedicated optical components and simplifying manufacturing.
4Reliability
If conventional illumination systems are used, then reliability is maintained, but space and material consumption increase
Solution Approach 1:
Thin-film optical elements and flexible light guide structures are used instead of bulky conventional optical components. These thin-film structures maintain optical reliability while consuming significantly less material and space, enabling compact illumination systems without sacrificing performance.
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, enhances illumination uniformity, reduces the number of light sources needed, and simplifies manufacturing, while providing space, material, and weight savings, along with improved adhesion and reduced manufacturing complexity.
Implementation Method 1
reflector design comprising at least one material layer provided preferably at least upon the light source and configured to reflect, optionally dominantly specularly, the light emitted by the light source and incident upon the reflective layer
Implementation Method 2
optically transmissive plastic layer, optionally of thermoplastic material such as polycarbonate, produced upon the first side of the substrate film
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 on the substrate film; and a plurality of top-emitting, bottom-installed light sources provided upon a first side of the substrate film to internally illuminate at least portion of the structure for external perception via associated outcoupling areas, wherein for each light source of the plurality of light sources there is 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 reflector design including at least one material layer, provided at least upon the light source and configured to reflect the light emitted by the light source and incident upon the reflective layer towards the plastic layer.