Flexible Phototherapy Mask With Metal-Grid Current Limiting
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Solution Overview
Problem
Conventional wearable phototherapy devices face challenges with flexibility, adaptability, heat management, and uniformity of light delivery due to bulky structures, inefficient electrical control, and opaque layers, leading to reduced treatment effectiveness and safety concerns.
Innovation Solution
A wearable phototherapy apparatus with a transparent, multi-layer structure incorporating micro-LEDs and a metal-grid current-limiting technology for precise light output, thermal dissipation, and ergonomic adaptability, featuring a flexible substrate and a thin-film conductive structure for secure electrical coupling and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional discrete resistors are soldered onto the circuit board to limit current, then current control is achieved, but the device becomes bulky and heat dissipation efficiency is reduced
Solution Approach 1:
The patent merges the current-limiting function with the circuit board trace structure itself, eliminating discrete resistors. The circuit board is designed with integrated current-limiting traces that directly control LED current without requiring separate resistor components, thereby reducing device bulk while maintaining reliable current control.
Solution Approach 2:
The circuit board serves multiple functions: it provides structural support, electrical connections, and integrated current-limiting control. The trace structure simultaneously acts as both the circuit pathway and the current-limiting element, reducing the need for separate components and simplifying the overall device architecture.
2Illumination intensity
If high-intensity LEDs are used to provide sufficient light output, then illumination intensity is improved, but heat accumulation increases causing discomfort and safety concerns
Solution Approach 1:
The patent converts the harmful heat generated by high-intensity LEDs into a beneficial thermal management feature. The circuit board's trace structure and metal grid are designed to act as heat dissipation pathways, conducting heat away from the LEDs and distributing it across the device structure, thereby maintaining high light output while preventing dangerous heat accumulation.
Solution Approach 2:
The circuit board and metal grid structure serve as thermal intermediaries between the high-intensity LEDs and the user's skin. These components conduct and distribute heat away from the LED sources, preventing direct heat transfer to the user while maintaining the high illumination intensity required for effective phototherapy.
3Device complexity
If standard LEDs are widely spaced on the circuit board, then device complexity is reduced, but light coverage becomes non-uniform leaving untreated areas
Solution Approach 1:
The patent segments the lighting function into multiple independent LED modules distributed across the treatment surface. Each module can be independently controlled and positioned to ensure uniform coverage. The circuit board is designed with modular trace structures that accommodate this segmented arrangement, allowing precise light distribution without excessive complexity.
Solution Approach 2:
The circuit board features locally optimized trace structures and LED positioning tailored to specific treatment zones. Different areas of the device have customized LED densities and trace configurations matched to the anatomical features of the treatment area, ensuring uniform light coverage while adapting to local requirements rather than using a uniform design throughout.
4Strength
If opaque or semi-opaque layers are used in device construction, then structural integrity is improved, but light transmission uniformity is limited
Solution Approach 1:
The patent employs thin, transparent or translucent film structures instead of opaque layers. These thin films provide the necessary structural integrity and protection while allowing uniform light transmission. The films are designed to be flexible and conformable to body contours, maintaining both strength and optical performance.
Solution Approach 2:
The device utilizes composite material structures combining transparent substrates, conductive traces, and protective coatings. These composite layers are engineered to provide structural support, electrical functionality, and optical clarity simultaneously, achieving both structural integrity and uniform light transmission through carefully selected material combinations.
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
Ensures uniform light delivery, improved safety, and comfort while conforming to different body contours, with enhanced thermal management and operational reliability, supporting various wearable configurations.
Implementation Method 1
a metal-grid current-limiting structure integrated into the circuit board... used to limit current to the LEDs
Implementation Method 2
transparent, multi-layer construction that enhances heat dissipation... uniformity of light distribution
Implementation Method 3
transparent, multi-layer construction that enhances heat dissipation
Data Source
AI summary
Embodiments of the present invention provide a wearable phototherapy device, comprising a flexible substrate supporting a plurality of light-emitting elements configured to emit therapeutic light of one or more wavelengths. The substrate conforms to a treatment surface and may be integrated into a mask, wrap, patch, or garment insert. A conductive thin-film layer with an integrated metal-grid structure limits current to the light-emitting elements. The elements are arranged in one or more treatment zones, each independently addressable to provide wavelength and intensity control. A connector assembly enables selective attachment and detachment of the substrate to a power and control module. The device provides uniform, targeted illumination for dermatological, cosmetic, or therapeutic applications while maintaining ergonomic comfort.