Flexible LED Strip With Dual-Sided Wiring for Bending Reliability
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Solution Overview
Problem
Existing flexible LED strips are prone to damage and circuit failure when bent or twisted, leading to poor contact or direct circuit breakage.
Innovation Solution
A flexible LED strip design featuring a long-strip-shaped insulating soft film with multiple first and second wires arranged for conduction, connected to LED pins, and reinforced with thickening parts and conductive convex contact members to enhance structural strength and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the flexible LED strip uses a sheet-like wire arrangement, then the structure is simple and easy to manufacture, but the wire is prone to damage and circuit breakage during bending or twisting
Solution Approach 1:
The patent divides the wire structure into multiple independent parallel wires (first wires and second wires) arranged on opposite sides of the insulating soft film. Each wire is independently connected to LED pins, creating multiple parallel conduction paths. This segmentation ensures that if one wire is damaged during bending, the circuit can still function through other wires, thereby improving reliability while maintaining manufacturing simplicity.
Solution Approach 2:
The patent transitions from a single-layer wire arrangement to a three-dimensional structure by placing wires on both the front and back surfaces of the insulating soft film. The first wires are arranged on one surface and the second wires on the opposite surface, creating spatial separation and redundancy. This dimensional arrangement prevents wire damage during bending while maintaining electrical conduction, resolving the contradiction between simplicity and reliability.
2Volume of moving object
If the flexible LED strip uses a thin structure to reduce space occupation, then the product is compact, but the strip is prone to breakage during bending or twisting
Solution Approach 1:
The patent employs a composite structure combining an insulating soft film with multiple conductive wires embedded on its surfaces. The insulating soft film provides a flexible, thin base layer that maintains compact dimensions, while the embedded wires (first wires and second wires) provide structural reinforcement and electrical conduction. This composite design allows the strip to remain thin and space-efficient while gaining the strength needed to resist breakage during bending or twisting.
3Adaptability or versatility
If the flexible LED strip uses SMD LEDs for assembling, then the product can be freely cut and extended, but the connection points are vulnerable to damage during bending
Solution Approach 1:
The patent performs preliminary reinforcement by positioning thickening parts at specific locations on the insulating soft film corresponding to the LED pin connection points. These thickening parts are formed by soldering tin or other conductive materials before the final assembly. This preliminary action strengthens the vulnerable connection areas, allowing the strip to be freely cut and extended while maintaining reliable electrical connections at the LED mounting points.
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 design improves the reliability and durability of the LED strip by preventing circuit breakage during bending, allowing for easy cutting and connection, and enhancing current carrying capacity.
Implementation Method 1
a long-strip-shaped insulating soft film
Implementation Method 2
the plurality of first wires are connected to each other for conduction; the plurality of second wires are connected to each other for conduction
Implementation Method 3
a thickening part is arranged on the surface of the other side of the insulating soft film in the lengthwise direction, and the thickening part is oriented towards the LEDs
Implementation Method 4
conductive convex contact members are arranged at positions, between two adjacent LEDs, on the second wires
Data Source
Figure 1~3
Figure 4
AI summary
A flexible light-emitting diode (LED) strip includes a long-strip-shaped insulating soft film . Two first wires and a plurality of LEDs are arranged on a surface of one side of the insulating soft film in a lengthwise direction. The two first wire are connected to each other for conduction, and the plurality of LEDs are located between the two first wires. Two second wires and a third wire are arranged on a surface of the other side of the insulating soft film in the lengthwise direction. The two second wires are arranged side by side in a width direction of the insulating soft film, and the third wire is located between the two second wires. The first wires are connected to one pin end of the LEDs, and the second wires are connected to the other pin end of the LEDs. The flexible LED strip has an overall simple structure and is convenient to process and manufacture. The two first wires are arranged on two sides of the insulating soft film, so that an effect of connecting wires can be achieved, and the overall strength of the structure can be improved. This can prevent a broken circuit in the strip caused by breakage of the first wire and the second wire on either side, and greatly improve the reliability of the strip.