A flexible silicone neon light strip

Abstract

This utility model discloses an arbitrary-bend silicone neon light strip, belonging to the field of LED lighting. It includes an FR-4 printed circuit board, silicone-plated copper wires for connecting the FR-4 printed circuit board in series, silicone sheathed wires for the first end of the lead wire, silicone sleeves, and end cap assemblies. LED beads are set on the FR-4 printed circuit board. This utility model's silicone neon light strip breaks through the unidirectional bending limitation of traditional FPCB light strips, realizing free bending in all dimensions such as longitudinal, lateral, and 360-degree twisting. It is suitable for complex shape designs in fields such as architectural decoration, art installations, and commercial displays, and can meet the needs of various complex shapes such as spheres, spirals, and irregular sculptures. At the same time, it has an IP67 protection rating and can be widely used in indoor and outdoor occasions. It can work normally in humid, dusty, and even short-term water immersion environments, adapting to various complex environments.

Description

Technical Field

[0001] This utility model relates to the field of LED lighting technology, and in particular to an arbitrary bendable silicone neon light strip. Background Technology

[0002] With the continuous development of lighting technology, LED silicone neon light strips, with their energy-saving and environmentally friendly properties, long lifespan, and rich colors, are now widely used in decoration, landscape lighting, machinery and equipment, and automotive ambiance. LED light strips typically consist of bare LED boards without any protection (i.e., LEDs are simply attached to a printed circuit board), LEDs embedded in an aluminum shell with adhesive, or a printed circuit board with attached LEDs encased in a plastic shell. Different types of LED light strips are selected depending on the indoor or outdoor application scenario.

[0003] Currently, the mainstream technology for LED silicone neon light strips in the market is based on a combination of flexible printed circuit boards (FPCBs) and silicone extrusion processes. This technology involves soldering LED beads onto the FPCB and then encapsulating them with silicone extrusion to form a light-emitting body with a certain degree of flexibility. The initial design of this type of light strip was intended to meet the bending installation requirements in certain scenarios. However, in practical applications, due to the directional flexibility of the FPCB—it is easy to bend longitudinally but has high lateral rigidity—the light strip can only bend in one direction (positive or side bending), and cannot achieve 3D bending (such as spirals, ring twists, etc.). This limits its application in complex shapes such as spheres, sculptural contours, and irregular decorative elements. Therefore, its bending direction is significantly limited, failing to meet the increasingly complex requirements of 3D shapes. Utility Model Content

[0004] The purpose of this invention is to solve the problem that existing traditional FPCB-based LED silicone neon light strips can only be bent in one direction and cannot meet the needs of 3D stereoscopic modeling, and to propose an arbitrary bending silicone neon light strip.

[0005] To achieve the above objectives, the present invention employs the following technology: an arbitrary bendable silicone neon light strip, comprising an FR-4 printed circuit board, silicone tinned copper wires for connecting the FR-4 printed circuit board in series, a silicone sheath wire for the first end lead wire, a silicone sleeve, and a plug assembly, wherein LED beads are provided on the FR-4 printed circuit board.

[0006] As a further description of the above technical solution: the silicone sleeve is provided with a buffer cavity and an installation cavity, and the LED beads, FR-4 printed circuit board and silicone tinned copper wire connected in a string to form a modular light string are inserted into the installation cavity of the silicone sleeve.

[0007] As a further description of the above technical solution: the plug assembly includes a blind end plug disposed at one end of the silicone sleeve and a plug end plug disposed at the other end of the silicone sleeve.

[0008] As a further description of the above technical solution: the FR-4 printed circuit board uses FR-4 glass fiber epoxy resin board as the base carrier.

[0009] As a further description of the above technical solution: the silicone tin-plated copper wire is made of highly flexible tin-plated copper wire and is covered with a low-hardness silicone rubber insulation layer.

[0010] As a further description of the above technical solution: the silicone sleeve is made of highly elastic silicone rubber material, and the light-emitting surface of the silicone sleeve is provided with nano-silica diffusing agent.

[0011] As a further description of the above technical solution: multiple FR-4 printed circuit boards are electrically connected by silicone-plated copper wires.

[0012] As a further description of the above technical solution: the plug end plug is adapted to the silicone sheathed wire, and both the blind end plug and the plug end plug are made of highly elastic silicone rubber.

[0013] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0014] 1. This utility model of silicone neon light strip breaks through the unidirectional bending limitation of traditional FPCB light strips, achieving free bending in all dimensions such as longitudinal, transverse, and 360-degree twisting. It is suitable for complex shape designs in fields such as architectural decoration, art installations, and commercial displays, and can meet the needs of various complex shapes such as spherical, spiral, and irregular sculptures. At the same time, it has an IP67 protection rating and can be widely used in indoor and outdoor occasions. It can work normally in humid, dusty, and even short-term water immersion environments, adapting to various complex environments.

[0015] 2. This utility model utilizes FR-4 printed circuit boards, which have high mechanical strength and can better maintain structural integrity and circuit stability during bending, providing more effective protection for components, reducing the failure rate of the light strip, and extending its service life. The nano-silica diffusing agent added to the light-emitting surface of the silicone sleeve makes the light soft and uniform with a wide beam angle, improving lighting quality and visual effects, and creating a more comfortable lighting atmosphere. With multiple FR-4 printed circuit boards, if one FR-4 printed circuit board is damaged, only that FR-4 printed circuit board needs to be replaced, without replacing the entire string. Furthermore, by increasing or decreasing the number of FR-4 printed circuit boards, the length of the light strip can be flexibly adjusted to meet the needs of different scenarios, thus improving the applicability of the product. Attached Figure Description

[0016] Figure 1 A schematic diagram of the overall structure according to an embodiment of the present utility model is shown;

[0017] Figure 2 An exploded view of the overall structure according to an embodiment of the present invention is shown;

[0018] Figure 3 A cross-sectional side view of a silicone sleeve provided according to an embodiment of the present invention is shown;

[0019] Figure 4 A schematic diagram of the overall bending state provided according to an embodiment of the present invention is shown.

[0020] Legend:

[0021] 1. LED beads; 2. FR-4 printed circuit board; 3. Silicone-plated tinned copper wire; 4. Silicone sleeve; 5. Blind end plug; 6. Plug end plug; 7. Silicone sheathed wire; 8. Buffer cavity; 9. Mounting cavity. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present utility model.

[0023] Reference Figures 1-4 This embodiment provides an arbitrary bendable silicone neon light strip, including an FR-4 printed circuit board 2, a silicone tinned copper wire 3 for connecting the FR-4 printed circuit board 2 in series, a silicone sheathed wire 7 for the first end of the wire, a silicone sleeve 4, and a plug assembly. Multiple FR-4 printed circuit boards 2 are electrically connected through the silicone tinned copper wire 3, and LED beads 1 are provided on the FR-4 printed circuit board 2.

[0024] Specifically, the preparation process of this utility model includes the following steps:

[0025] 1. Modular lamp panel fabrication:

[0026] Carrier selection: FR-4 glass fiber epoxy resin board is selected as the base carrier. FR-4 material has excellent mechanical strength and can withstand a certain amount of external force without deformation. At the same time, it has excellent electrical insulation properties, which can effectively prevent problems such as short circuits. It provides a stable and reliable mounting base for LED lamp beads 1 and surface mount components, ensuring that the structural integrity and circuit stability of the lamp board are maintained during subsequent bending processes.

[0027] Component mounting: High-precision surface mount technology (SMT) is used to precisely solder the LED beads 1 and related surface mount components onto the surface of the FR-4 printed circuit board 2. SMT technology enables high-precision positioning of components, with positioning accuracy controllable within ±0.05mm, ensuring that the position of each component is accurate. This ensures the stability and reliability of the circuit during subsequent circuit connection and LED strip operation. During the mounting process, the soldering temperature and time are strictly controlled. The soldering temperature is set between 230-250℃ and the soldering time is 3-5 seconds to ensure soldering quality and avoid issues such as cold solder joints or false solder joints.

[0028] Wiring optimization: The wiring design of the lamp board is optimized, and the circuit routing is planned in a reasonable way to make the layout of power lines, signal lines, etc. clear and reasonable, reducing interference between lines. At the same time, the copper foil width of the lines is increased, and the copper foil width of the power lines is not less than 1.5mm, in order to reduce the line resistance and ensure that the current can be smoothly transmitted between the components. This prepares for the subsequent series integration of multiple FR-4 printed circuit boards 2, ensuring that the series lamp string can light up normally and with stable performance.

[0029] 2. Module series integration:

[0030] Conductor fabrication: High-flexibility tin-plated copper wire with a diameter of 0.5-0.8 mm is selected, possessing excellent conductivity. To further improve its performance during bending, a low-hardness silicone rubber insulation layer with a thickness of 0.2-0.3 mm is wrapped around the tin-plated copper wire to form silicone tin-plated copper wire 3. This silicone tin-plated copper wire 3 has a volume resistivity of less than 1×10⁻⁶. -7 With a strength of Ω·m, it can ensure good conductivity, allowing current to pass through smoothly. At the same time, the flexibility of the silicone rubber insulation layer allows the connection part to deform flexibly when the light strip is bent, so that the wire will not break or make poor contact due to bending.

[0031] Module soldering: Using the prepared silicone-plated copper wire 3, multiple pre-prepared FR-4 printed circuit boards 2 are soldered together. During the soldering process, a constant temperature soldering iron is used, with the temperature set to 260-280℃ to ensure that the solder joints are firm and reliable. The soldering time for each solder joint is 2-3 seconds to avoid cold solder joints and other issues, so as to ensure that the power and control signals can be stably transmitted between the various FR-4 printed circuit boards 2. Through this series connection, multiple FR-4 printed circuit boards 2 are connected into a complete LED light string system. This series structure ensures that the overall light emission of the light strip is consistent, and the light intensity difference is controlled within ±5%, so that some LEDs are bright and some LEDs are dim.

[0032] Length Adjustment: Since the LED strip is connected in series by welding wires, the number of FR-4 printed circuit boards 2 can be flexibly increased or decreased according to actual application needs, thereby adjusting the length of the LED strip. For example, in shorter decorative line applications, the number of FR-4 printed circuit boards 2 can be reduced to control the length of the LED strip to 0.5-1 meter. In large-scale landscape lighting, the number of modules can be increased to make the length of the LED strip reach 5-10 meters or even longer, meeting the requirements for LED strip length in different scenarios. At the beginning of the LED string, silicone sheathed wire 7 is used for the exit. The conductor of the silicone sheathed wire 7 is also tinned copper wire, wrapped with a silicone rubber insulation layer, which has good flexibility and insulation performance, further ensuring the reliability of the connection between the LED string and the external power supply or control equipment.

[0033] 3. Packaging:

[0034] Sleeve Material and Preparation: The formed LED light string is inserted into a specially made silicone sleeve 4. The blind end plug 5 and plug end plug 6, which are formed by hot pressing, are seamlessly fitted with the extruded silicone sleeve to improve the sealing performance. The silicone sleeve 4 is made of highly elastic silicone rubber material with an elongation at break of more than 300%. It is made through a precise extrusion process. During the extrusion process, the extrusion temperature is strictly controlled. The barrel temperature is set to 120℃, 150℃ and 170℃ from the feed port to the discharge port, and the die temperature is 160℃ to ensure the forming quality of the sleeve. This gives it good flexibility and tear resistance, with a tear strength of more than 20kN / m. It can deform with the bending of the light strip, while ensuring that the sleeve will not be easily damaged after long-term use and multiple bending.

[0035] Buffer cavity design: The sleeve is designed with an adaptive buffer cavity 8 structure. When the light strip is bent, this buffer cavity can deform to absorb the stress generated during the bending process. Tests have shown that with a bending radius of 10mm, the cavity can effectively absorb more than 90% of the bending stress, preventing the LED beads 1 and the internal circuitry from being damaged by compression, effectively protecting the internal structure of the light strip and extending its service life.

[0036] Light-emitting surface treatment: Nano-sized silica diffusing agent is added to the light-emitting surface of the silicone sleeve 4, with an addition amount of 5%-8% of the mass of the silicone material. When the LED bead 1 emits light, the light is effectively diffused by the diffusing material, so that the light emission angle reaches 120°-150°, thereby achieving a soft and uniform light emission effect and improving the lighting quality and visual effect of the light strip.

[0037] Protection rating: The encapsulated LED strip undergoes a comprehensive test, including a light emission test, a bending test, and a waterproof test. During the bending test, the LED strip is bent longitudinally, laterally, and twisted 360 degrees. After the bending test, a light emission test is performed again to ensure that the LED strip can still emit light normally after bending and that the circuit is stable. The waterproof test is conducted according to the IP67 standard, in which the LED strip is immersed in 1 meter of water for 30 minutes. After removal, a light emission test is performed. The LED strip should be able to emit light normally without any water ingress.

[0038] Furthermore, the silicone sleeve 4 has a buffer cavity 8 and an installation cavity 9 inside, and the LED beads 1, FR-4 printed circuit board 2 and silicone tinned copper wire 3 are connected in a string to form a modular light string, which is inserted into the installation cavity 9 of the silicone sleeve 4.

[0039] Specifically, the buffer cavity 8 can be compressed and deformed when the silicone sleeve 4 is bent, absorbing more than 90% of the bending stress and preventing the LED beads 1 from being damaged by pressure. The connected module light string is inserted into the silicone sleeve 4. After insertion, the gap between the light string and the sleeve is fixed by the "silicone positioning point" to prevent the module light string from shifting in the silicone sleeve 4, while ensuring that the positioning point can withstand the subsequent hot pressing molding temperature.

[0040] Furthermore, the plug assembly includes a blind end plug 5 disposed at one end of the silicone sleeve 4 and a plug end plug 6 disposed at the other end of the silicone sleeve 4. The plug end plug 6 is adapted to the silicone sheathed wire 7. Both the blind end plug 5 and the plug end plug 6 are made of highly elastic silicone rubber.

[0041] Specifically, the first end of the light string uses a silicone sheathed wire 7 as the power lead, with a length of 150mm. The end is stripped by 5mm and crimped with a terminal for easy connection to an external power supply or controller. Polyimide tape is wrapped around the welding joint between the silicone sheathed wire 7 and the light string to enhance insulation and prevent high-temperature damage to the welding point during hot pressing. The blind end plug 5 and the plug end plug 6 use liquid silicone rubber as the molding material. This material has the characteristics of high elasticity, high temperature resistance, strong weather resistance, and excellent waterproof performance. After hot pressing, it can form a seamless fit with the silicone sleeve 4, improving the sealing performance.

[0042] Furthermore, the FR-4 printed circuit board 2 uses FR-4 glass fiber epoxy resin board as the base carrier. This material has the characteristics of high mechanical strength, excellent electrical insulation and good temperature resistance. It can maintain the structural integrity during bending and prevent the LED beads 1 from falling off the surface mount components.

[0043] Furthermore, the silicone tinned copper wire 3 uses highly flexible tinned copper wire as the conductor and is covered with a low-hardness silicone rubber insulation layer. The bending fatigue life of this wire is ≥10,000 times and the DC resistance is ≤0.08Ω / m, ensuring both conductivity and bending performance.

[0044] Furthermore, the silicone sleeve 4 is made of highly elastic silicone rubber material and is extruded through a precision extrusion process. The inner diameter of the sleeve is 0.5 to 1 mm larger than the outer diameter of the light string to ensure that the light string can be smoothly inserted. The light-emitting surface of the silicone sleeve 4 is provided with nano-silica diffusing agent to make the light diffuse evenly and avoid the "light spot" phenomenon.

[0045] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. An arbitrary bending silicone neon light strip, characterized in that, The FR-4 printed circuit board (2) includes a silicone tinned copper wire (3) for connecting the FR-4 printed circuit board (2) in series, a silicone sheathed wire (7) for the first end of the wire, a silicone sleeve (4) and a plug assembly. The FR-4 printed circuit board (2) is provided with LED beads (1).

2. The arbitrary bending silicone neon light strip according to claim 1, characterized in that, The silicone sleeve (4) has a buffer cavity (8) and an installation cavity (9) inside, and the LED beads (1), FR-4 printed circuit board (2) and silicone tinned copper wire (3) are connected in a string to form a modular light string, which is inserted into the installation cavity (9) of the silicone sleeve (4).

3. The arbitrary bending silicone neon light strip according to claim 1, characterized in that, The plug assembly includes a blind end plug (5) disposed at one end of the silicone sleeve (4) and a plug end plug (6) disposed at the other end of the silicone sleeve (4).

4. The arbitrary bending silicone neon light strip according to claim 1, characterized in that, The FR-4 printed circuit board (2) uses FR-4 glass fiber epoxy resin board as the base carrier.

5. The arbitrary bending silicone neon light strip according to claim 1, characterized in that, The silicone tinned copper wire (3) is made of highly flexible tinned copper wire and is covered with a low-hardness silicone rubber insulation layer.

6. The arbitrary bending silicone neon light strip according to claim 1, characterized in that, The silicone sleeve (4) is made of highly elastic silicone rubber material, and the light-emitting surface of the silicone sleeve (4) is provided with nano-silica diffuser.

7. The arbitrary bending silicone neon light strip according to claim 1, characterized in that, Multiple FR-4 printed circuit boards (2) are electrically connected by silicone-plated copper wires (3).

8. The arbitrary bending silicone neon light strip according to claim 3, characterized in that, The plug end plug (6) is compatible with the silicone sheath wire (7), and both the blind end plug (5) and the plug end plug (6) are made of high elastic silicone rubber.

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