A flexible LED light strip with built-in reinforcement protection

Abstract

The utility model discloses a built -in reinforced protection's flexible LED lamp area, including the flexible circuit board of strip shape, and set up on the LED lamp pearl of flexible circuit board, the long strip structural member is inlayed below LED lamp pearl in the flexible circuit board, the long strip structural member is with the long strip shape of matching of flexible circuit board, and the thickness is 0.05 0.5mm, and through the lamination technology inlaying between the flexible substrate layer and the film layer of flexible circuit board. The structure utilizes the long strip structural member of inlaying and provides direct, stable mechanical support for LED lamp pearl, can effectively disperse the stress produced when the lamp area is bent, twisted, prevents LED weld point and damages because of stress concentration, and fundamentally solves the problem that traditional outer -sticking reinforcing structure is easy to delaminate and fall off. The utility model has simple structure, and good compatibility with roll -to -roll production process, and the effect is remarkable in improving product reliability and service life.

Description

Technical Field

[0001] This utility model relates to the field of LED lighting technology, specifically to a flexible LED light strip with built-in reinforced protection. Background Technology

[0002] Flexible LED light strips, as an important branch of modern lighting, have been widely used in architectural contour lighting, interior decoration, advertising signs, and atmosphere creation for various special scenarios due to their unique advantages of high energy efficiency, long lifespan, and flexibility and customizability. Their core structure typically uses flexible circuit boards as the substrate, and LED chips and necessary electronic components are integrated onto them using surface mount technology, thereby achieving flexible and modular lighting.

[0003] However, this very flexibility, while bringing ease of installation and design freedom, also introduces inherent challenges to mechanical reliability. During actual installation, use, and subsequent maintenance, the LED strip inevitably needs to be repeatedly bent and twisted to adapt to complex spatial contours. Furthermore, for packaging, transportation, and storage purposes, finished LED strips are usually stored in a coiled state, which often differs from the bending shape and radius used in actual applications. These dynamic and uncertain mechanical stresses directly act on the most vulnerable parts of the structure—the solder joints of the LED components and their encapsulation. Long-term or severe stress concentration can easily lead to irreversible damage such as solder joint fatigue fracture and chip detachment from the substrate, ultimately causing partial or overall failure of the LED strip, severely impacting product lifespan and user experience.

[0004] To address these issues, the industry has proposed various technical solutions to enhance the mechanical strength of flexible LED light strips. One mainstream approach is to add reinforcing components to the back of the flexible circuit board. For example, Chinese patent document CN102287670A discloses a reinforced flexible LED light strip, which involves using an adhesive to attach a specific reinforcing layer to the back of the light strip. While this method improves the straightness of the light strip to some extent, its reliance on the physical properties of the adhesive constitutes a new technical bottleneck. Over prolonged use, especially under harsh environments such as temperature and humidity cycles and chemical corrosion, the adhesive layer is at risk of aging and embrittlement, leading to a degradation in bonding performance and ultimately causing localized or large-area debonding (non-adhesion) between the reinforcing layer and the light strip body. This debonding phenomenon is particularly pronounced when the light strip experiences internal shear stress due to changes in its bending radius. Specifically, during bending and curling, the radii of the reinforcing layer and the light strip body are different, resulting in different arc lengths at the same angle. This causes a persistent splitting force between the reinforcing layer and the light strip body, which, over time, leads to splitting, arching, and other undesirable phenomena.

[0005] Another common improvement is to attach metal reinforcing sheets, such as thin steel sheets, to the corresponding positions of the LED components on the back of the light strip using adhesive bonding. While this solution provides significant local rigidity, individually attaching reinforcing sheets to the back of each LED component results in a complex manufacturing process, high process requirements, low yield, high cost, and is not conducive to mass production, rapid production, or cost-effectiveness.

[0006] In summary, existing technologies that use externally bonded reinforcing components generally suffer from insufficient reliability in their bonding with the LED strip body and are prone to delamination failure under dynamic bending conditions. Therefore, there is an urgent need in this field for a novel structural reinforcement solution that ensures a stable and durable integrated structure between the reinforcing component and the flexible LED strip body, thereby fundamentally overcoming the risk of delamination and achieving efficient and reliable stress protection for LED components. Utility Model Content

[0007] To address the problems existing in the prior art, this utility model provides a flexible LED light strip with built-in reinforcement protection. By embedding the reinforcement structure inside the flexible circuit board, the structure and function are integrated, thereby significantly improving the light strip's resistance to bending and torsion, extending its service life, and facilitating stable mass production.

[0008] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0009] A flexible LED light strip with built-in reinforcement and protection includes a long, flexible circuit board and LED beads disposed on the flexible circuit board. An elongated structural member is embedded below the LED beads in the flexible circuit board to provide support and protection for the LED beads when bent. The elongated structural member is elongated and matches the shape of the flexible circuit board. This elongated structural member is not a component of the circuitry but only serves a mechanical reinforcement function.

[0010] Specifically, the width of the elongated structural member is slightly larger than the width of the installation location of the LED beads to ensure effective coverage and protection of the LEDs.

[0011] Specifically, the width of the elongated structural member is smaller than the width of the flexible circuit board, and its length matches the length of the flexible circuit board, so as to ensure the enhancement effect without affecting the overall shape and lateral bending flexibility of the light strip.

[0012] Specifically, the long strip structure is a polyimide film or a steel sheet, and different materials can be selected according to the actual application.

[0013] Specifically, the thickness of the elongated structural member is between 0.05mm and 0.5mm, which achieves the best balance between providing sufficient protective rigidity and maintaining the overall flexibility of the light strip.

[0014] Specifically, the flexible circuit board includes a flexible substrate layer carrying conductive lines and a coating layer tightly adhered to the back side of the flexible substrate layer. The elongated structural member is embedded between the flexible substrate layer and the coating layer, and is integrated into a single package through a lamination process, resulting in a stable structure with no risk of detachment. This built-in elongated structure facilitates stable mass production with high yield, thereby improving the efficiency and product consistency of elongated circuit boards, especially in roll-to-roll production processes.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] (1) This utility model replaces the traditional external adhesive with a physical bonding method of lamination and embedding, which realizes a stable and interface-free bond between the long strip structure and the flexible circuit board body. It completely eliminates the risk of debonding caused by the aging and embrittlement of the adhesive under bending stress, thereby ensuring the durability and stability of the enhanced protection and enabling the product to adapt to more complex and harsh application environments.

[0017] (2) By directly and accurately embedding the long strip structure directly below the LED beads in the critical stress area, this utility model realizes that when the light strip is bent, the external stress is first absorbed and redistributed by the high modulus long strip structure, which effectively avoids the stress being directly concentrated on the fragile LED solder joints, thereby minimizing the risk of solder joint fatigue fracture or chip damage caused by bending and twisting. According to test analysis, the repeated bending life of the light strip can be increased by more than 30%.

[0018] (3) This utility model seamlessly integrates the embedding process of the long strip structure with the long plate or roll-to-roll production process of the flexible circuit board, realizing the completion of positioning, lamination and packaging on a continuous production line. This not only eliminates the independent process of subsequent bonding of reinforcing sheets in the traditional solution, shortens the production cycle and reduces production costs, but also ensures the accuracy of the position of the reinforcing parts and the consistency of the bonding quality in each product through automated equipment, thereby greatly improving the yield and quality stability of the products.

[0019] (4) By designing the width and thickness of the long strip structure, this utility model achieves sufficient support rigidity in the LED installation area while retaining the necessary flexibility on both sides and the whole of the light strip. This allows the light strip of this utility model to resist bending deformation in the required direction to protect the LED, and to be easily bent in other directions to adapt to complex installation contours. Thus, it achieves an excellent balance between mechanical protection and installation flexibility, and broadens its application range. Attached Figure Description

[0020] Figure 1 This is a cross-sectional structural diagram of an embodiment of the present invention.

[0021] Figure 2 This is an exploded three-dimensional structural diagram of an embodiment of the present invention. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments. The embodiments of the present invention include, but are not limited to, the following embodiments.

[0023] Example

[0024] like Figures 1 to 2 As shown, the flexible LED light strip with built-in reinforced protection includes a long, flexible circuit board 1, multiple LED beads 2 disposed on the flexible circuit board, and a long structural member 3 embedded in the flexible circuit board and located below the LED beads. The flexible circuit board includes a flexible substrate layer 11 carrying conductive lines and a coating layer 12 tightly attached to the back side of the flexible substrate layer; conductive lines (not shown in the figure) are formed on the flexible substrate layer by an etching process, and the LED beads are soldered to designated positions on the upper surface of the flexible substrate layer.

[0025] The key to this implementation lies in embedding a long strip structure 3, the same length as the LED strip, between the flexible substrate layer 11 and the coating layer 12. This strip structure does not serve as a circuit component but only provides mechanical reinforcement. Preferably, this long strip structure can be a polyimide film or a steel sheet with a thickness between 0.05mm and 0.5mm. Different materials can be selected according to the actual application. For example, in this embodiment, a 0.1mm thick 304 stainless steel sheet is selected. Its width is slightly wider than the installation area of ​​the LED beads but narrower than the total width of the flexible circuit board, thus ensuring the reinforcement effect without affecting the overall shape and lateral bending flexibility of the LED strip.

[0026] During production, a roll-to-roll (R2R) process can be used. R2R is a continuous production process widely used in the manufacturing of LED light strips. This process involves continuously processing flexible substrates (flexible circuit boards, plastic films, etc.) in roll form. From raw material feeding, printing, mounting, and encapsulation to the final winding of the finished product, the entire process is uninterrupted, achieving highly efficient and automated production. The specific process is as follows: First, the long strip structure is placed on the film layer or flexible substrate layer for pre-positioning. Then, the flexible substrate layer with the LED chips already mounted is aligned with the film layer, and the two are firmly bonded together through a hot-pressing process. Finally, the long strip structure is completely encapsulated within the flexible circuit board, forming a single unit.

[0027] This invention, through its structural design, enables the internal forces of the LED light strip to be effectively transmitted and dispersed through the embedded elongated structural components when the LED light strip is bent or twisted, thereby protecting the most vulnerable LED chip solder joints and significantly improving the product's durability and reliability.

[0028] The above embodiments are merely preferred embodiments of this utility model and are not intended to limit the scope of protection of this utility model. Any changes made based on the design principles of this utility model, or any non-creative changes made on this basis, shall fall within the scope of protection of this utility model.

Claims

1. A flexible LED light strip with built-in reinforced protection, comprising a long strip-shaped flexible circuit board and LED beads disposed on the flexible circuit board, characterized in that, An elongated structural component is embedded in the flexible circuit board below the LED beads to protect them. The elongated structural component is elongated and matches the flexible circuit board.

2. The flexible LED light strip with built-in reinforced protection according to claim 1, characterized in that, The width of the elongated structural member is greater than the width of the installation location of the LED beads.

3. The flexible LED light strip with built-in reinforced protection according to claim 1, characterized in that, The width of the elongated structural member is smaller than the width of the flexible circuit board, and its length matches the length of the flexible circuit board.

4. The flexible LED light strip with built-in reinforced protection according to claim 1, characterized in that, The elongated structural component is a polyimide film or a steel sheet.

5. The flexible LED light strip with built-in reinforced protection according to claim 1, characterized in that, The thickness of the elongated structural member is between 0.05 mm and 0.5 mm.

6. The flexible LED light strip with built-in reinforced protection according to any one of claims 1 to 5, characterized in that, The flexible circuit board includes a flexible substrate layer carrying conductive lines and a coating layer tightly attached to the back side of the flexible substrate layer, with the elongated structural member embedded between the flexible substrate layer and the coating layer.

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