Marine navigation light with flexible circuit
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Solution Overview
Problem
Existing marine navigation lights face challenges in achieving consistent light intensity and angle specifications over regulated distances while maintaining a compact size, particularly for vessels under 12 meters in length, due to the larger source size of LEDs and the need for increased baffle radii to meet regulatory requirements.
Innovation Solution
The use of flexible printed circuits wrapped around a core with strategically positioned LEDs, both inward and outward facing, to create specific light patterns, combined with thermal management features to ensure compliance with navigation light standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If larger LED source size is used to meet intensity requirements, then light intensity is improved, but the physical size of the navigation light assembly increases
Solution Approach 1:
The patent divides the navigation light assembly into multiple segments: a compact core structure, a flexible circuit board wrapped around the core, and multiple smaller LEDs arranged in specific patterns. This segmentation allows achieving required intensity through coordinated arrangement of multiple small light sources rather than relying on a single large LED, thus maintaining compact size while meeting intensity requirements
Solution Approach 2:
The patent transitions from a planar LED arrangement to a three-dimensional configuration by wrapping the flexible circuit board around the core in a cylindrical geometry. This dimensional change enables compact packing of multiple LEDs in a small volume while maintaining precise angular control of light distribution patterns required for navigation lights
2Manufacturing precision
If baffle radius is increased to meet angle cutoff tolerances, then angle precision is improved, but the physical size of the assembly increases
Solution Approach 1:
The patent employs a curved cylindrical geometry for the flexible circuit board wrapped around the core, replacing traditional flat or planar baffle structures. This curvature enables precise angular control of light distribution by positioning LEDs at specific angular intervals around the core, achieving required angle cutoff tolerances within a compact cylindrical footprint rather than requiring large radial dimensions
Solution Approach 2:
The flexible circuit board serves multiple functions simultaneously: it provides structural support for mounting LEDs, acts as a thermal management pathway, enables precise angular positioning of light sources through its curved geometry, and facilitates electrical connections. This multi-functionality eliminates the need for separate baffle components, maintaining compact size while achieving angle precision
3Manufacturing precision
If multiple LEDs are arranged in complex patterns to meet light distribution requirements, then light pattern precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functional elements into a single integrated flexible circuit board structure that is wrapped around the core. The circuit board simultaneously provides mechanical support, electrical connections, thermal management, and precise angular positioning for multiple LEDs. This merging reduces device complexity by eliminating separate components while maintaining the ability to create precise light patterns through strategic LED placement on the curved surface
Solution Approach 2:
The patent uses a flexible printed circuit board as both a structural and functional element. The flexibility allows the circuit board to conform to the cylindrical core geometry, enabling compact three-dimensional arrangement of LEDs in precise angular patterns. This flexible thin-film approach achieves light pattern precision without requiring complex rigid mechanical structures or multiple separate components
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
This configuration reduces the physical size and thermal impact of navigation lights, while maintaining required light intensity and angle specifications, ensuring compliance with maritime safety regulations and enhancing navigation visibility.
Implementation Method 1
an LED navigation light that uses a flexible electrical circuit carrying LEDs wrapped around a core
Data Source
AI summary
An LED navigation light comprising a flexible electrical circuit with LEDs wrapped around a core, wherein at least one LED faces inward, and light output is shaped by the core's openings and/or portions of the flexible electrical circuit.