Conformal Lens for Chip-on-Board LED Lighting
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Solution Overview
Problem
Existing small lighting devices, such as keychain lights, rely on non-rechargeable button-cell batteries and separate packaged LEDs, which are costly, inefficient, and difficult to assemble, lacking the ability to provide high light intensity in a compact form.
Innovation Solution
A lighting device featuring a rechargeable battery, a chip-on-board LED arrangement, and a conformal lens, where the LED circuit board is mounted within a key-shaped housing, with a translucent or transparent coating to serve as both a lens and a sealant, simplifying assembly and enhancing light output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If separate packaged LEDs are used, then light emission function is achieved, but device size increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple LEDs into a single integrated LED array package mounted on a circuit board, eliminating the need for separate packaged LEDs. This merging approach maintains high light output while significantly reducing device size and simplifying assembly, directly resolving the contradiction between light emission capability and compact form factor.
Solution Approach 2:
The circuit board serves multiple functions: it provides structural support, electrical connections, and mounting for the LED array. This multi-functional design eliminates the need for separate mounting structures and wiring harnesses, reducing overall device volume while maintaining full lighting functionality.
2Illumination intensity
If separate packaged LEDs are used, then light emission is achieved, but assembly cost increases
Solution Approach 1:
By integrating multiple LEDs into a single array mounted on a circuit board, the patent reduces the number of individual assembly steps. Instead of handling and positioning separate packaged LEDs, the entire array is installed as one unit, significantly reducing assembly time and labor costs while maintaining high light output.
Solution Approach 2:
The LED array is pre-assembled and tested on the circuit board before final device assembly. This preliminary preparation allows for quality control and ensures proper electrical connections are made beforehand, reducing on-site assembly complexity and cost.
3Illumination intensity
If conventional lens assembly is used, then light directionality is achieved, but device complexity increases
Solution Approach 1:
The patent integrates the lens function directly into the LED array assembly, where the lens acts as both a protective cover and a light-directing element. This eliminates the need for separate lens components and mounting mechanisms, reducing device complexity while maintaining effective light directionality.
Solution Approach 2:
The conformal coating serves multiple functions simultaneously: it protects the circuit board and LEDs from environmental factors, provides structural sealing, and directs light output. This multi-functional design eliminates the need for separate protective and optical components, simplifying the overall device structure.
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 provides a compact, economical, and high-intensity lighting solution that is rechargeable, reducing assembly costs and improving light output while maintaining a small form factor, and the conformal coating enhances durability and moisture resistance.
Implementation Method 1
one or more light emitting diodes mounted to a circuit board
Implementation Method 2
a translucent or transparent conformal lens formed to cover the one or more light emitting diodes
Data Source
AI summary
A method for making a lighting device includes: obtaining a circuit board having one or more light emitting devices; obtaining a housing configured to receive the circuit board; placing the circuit board in the housing; then dispensing a conformal coating material onto the circuit board; allowing the dispensed conformal coating material to spread and level; and curing the conformal coating material to form a cover or lens on the circuit board. A lighting device may include: a housing configured to receive a light emitting circuit and a battery; a light emitting circuit including one or more light emitting diodes mounted to a circuit board; a translucent or transparent conformal lens formed to cover the one or more light emitting diodes; and an electrical switch for selectively energizing the light emitting diodes to produce light. The housing may be in a shape resembling a key.