Flame-Rated Circuit Board for Solid State Lighting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current lighting devices with solid state light emitters face challenges in achieving high energy efficiency and meeting flame-rating requirements, especially when operating at higher voltages, which often necessitate the use of expensive and luminescence-loss-prone flame-rated lenses.
Innovation Solution
The integration of a flame-rated optic directly attached to a solid state light emitter circuit board, which functions as the light source, eliminating the need for additional flame barriers and using index-matching materials to minimize light absorption and Fresnel losses, allows for higher voltage operation without large, costly lenses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flame-rated lenses are used to meet regulatory requirements for higher voltage applications, then safety requirements are satisfied, but optical efficiency decreases due to luminescence losses and device cost increases
Solution Approach 1:
The patent combines the flame-rated requirement directly into the circuit board substrate by using a flame-rated polymer material for the board itself, eliminating the need for separate flame-rated lenses. This integration maintains safety compliance while removing the optical losses associated with traditional flame-rated lens materials.
Solution Approach 2:
The patent extracts the flame-rating function from the optical lens and relocates it to the circuit board substrate. This separation allows the lens to be made from standard optically clear materials without flame-rating constraints, thereby preserving optical efficiency while the substrate provides the required fire safety properties.
2Reliability
If flame-rated lenses are used to meet regulatory requirements for higher voltage applications, then safety requirements are satisfied, but device cost increases
Solution Approach 1:
The flame-rated properties are merged into the circuit board substrate material itself, which is already a necessary component of the device. This eliminates the need for additional expensive flame-rated lens materials and reduces overall device cost while maintaining safety compliance.
Solution Approach 2:
The flame-rating requirement is extracted from the optical path components (lenses) and assigned to the structural substrate. This allows the use of cost-effective standard materials for optics while meeting safety requirements through the substrate material selection.
3Loss of energy
If index-matching materials are used to minimize Fresnel losses, then optical efficiency improves, but device complexity increases
Solution Approach 1:
The index-matching function is merged with the structural support function by making the circuit board substrate itself serve as the index-matching element. This eliminates the need for separate index-matching layers or gels, reducing device complexity while maintaining optical efficiency.
Solution Approach 2:
The substrate material is selected to have specific local optical properties (refractive index matching) at the interface with the light emitters. This localized optimization of material properties achieves optical efficiency without requiring complex multi-layer structures throughout the entire device.
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 solution enables smaller, more efficient, and cost-effective lighting systems with improved thermal performance and optical efficiency, while meeting regulatory requirements for higher voltage applications.
Implementation Method 1
using index-matching materials to minimize light absorption and Fresnel losses
Data Source
AI summary
A lighting device comprises a solid state light emitter on a circuit board, and an optic held in place relative to the first circuit board, a voltage drop across the emitter at least 60 volts. A lighting device comprises a solid state light emitter on a first circuit board, an optic held in place relative to the first circuit board, and a non-isolated power supply. A lighting device comprises a solid state light emitter on a first circuit board, and a flame-rated optic held in place relative to the first circuit board. An optic, comprising a translucent region, a first dimension not larger than about 10 mm, a second dimension not larger than 15 mm. A flame-rated optic comprising a translucent region, structure configured to hold the optic in place relative to a circuit board. Methods of making lighting devices.