3D-Formed Recess Substrate for Multilayer Light Source Isolation
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Solution Overview
Problem
Multilayer structures with integrated light-emitting components face challenges such as light leakage and crosstalk due to mutual disturbances between multiple radiation sources, leading to uncontrollable and inefficient light distribution, which complicates the design and thickness of the structure.
Innovation Solution
A multilayer structure featuring a flexible substrate with 3D-shaped recesses for aligned light sources and a thermoplastic optically transmissive light-guiding material layer that enables total internal reflection, minimizing light leakage and enhancing optical efficiency by aligning light sources with dedicated protrusions and indicator elements to control light propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple light sources are integrated in the same structure, then lighting coverage is improved, but light leakage and crosstalk increase due to mutual disturbances
Solution Approach 1:
The patent divides the structure into multiple recesses, each housing a separate light source. These recesses act as isolated compartments that segment the light paths, preventing mutual interference between adjacent light sources while maintaining comprehensive lighting coverage across the entire structure.
Solution Approach 2:
Each recess is designed with specific local optical properties including reflective surfaces positioned at defined angles (e.g., 45 degrees) to redirect light in controlled directions. This local optimization of light reflection and directionality ensures that each light source illuminates its designated area effectively without causing crosstalk to adjacent regions.
2Manufacturing precision
If light control features are added to correct light paths, then light distribution control is improved, but local material thickness increases considerably
Solution Approach 1:
Instead of adding thickness in the vertical dimension to control light paths, the patent utilizes the horizontal and angular dimensions by positioning reflective surfaces at specific angles within the recesses. This dimensional approach allows precise light path control without increasing the overall material thickness of the structure.
Solution Approach 2:
The recesses are designed with curved or angled surfaces that naturally redirect light paths through geometric configuration rather than requiring additional thick material layers. The curved geometry of the recesses and reflective surfaces enables efficient light direction control while maintaining a thin overall profile.
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 reduces light leakage and crosstalk, achieving uniform and efficient light distribution with minimal material thickness, allowing for dynamic control of lighting effects and improved integration in various applications.
Implementation Method 1
a thermoplastic optically transmissive light-guiding material layer (106)... configured to support total internal reflection based propagation of light therewithin enabled by an interface between the side walls of the protrusions and the neighbouring material
Data Source
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Figure 3A~3B
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AI summary
Embodiments of light-emittting multilayer structures incorporating substrate films (102) 3D-formed with recesses (116) for light sources (104) and plastics material (106) molded thereupon are presented. Related methods of manufacture are set forth as well.