Flex DLE Reflector Lamp PCB Thermal Isolation
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Solution Overview
Problem
Existing light fixtures with separate lighting element and electronic driver circuit boards are complex, costly, and prone to thermal issues due to the need for additional cooling components and increased weight, while integrating these components on a common circuit board can lead to overheating and increased manufacturing complexity.
Innovation Solution
A light fixture design featuring a printed circuit board with a deformation zone that electrically connects the lighting elements and electronic driver, providing thermal isolation and eliminating the need for additional parts, allowing for a simpler structure and reduced manufacturing costs by using a single, flexible printed circuit board with conductive tracks for electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate lighting element circuit board and electronic driver circuit board are used, then thermal isolation between components is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The printed circuit board is segmented into a first region for mounting lighting elements and a second region for mounting the electronic driver, connected by a deformation zone. This segmentation allows thermal isolation between components while maintaining a single integrated board structure, avoiding the complexity of multiple separate boards and their interconnections.
Solution Approach 2:
The deformation zone acts as an intermediary between the first region and second region, providing both mechanical flexibility and thermal isolation. This intermediate structure enables the board to accommodate thermal expansion differences while maintaining electrical connectivity through conductive tracks, resolving the contradiction between thermal isolation and structural simplicity.
2Temperature
If separate lighting element circuit board and electronic driver circuit board are used, then thermal isolation is achieved, but production cost increases
Solution Approach 1:
The patent merges the lighting element circuit board and electronic driver circuit board into a single printed circuit board with distinct functional regions. This consolidation eliminates the need for separate board production and assembly, reducing manufacturing complexity and cost while maintaining thermal isolation through the deformation zone design.
Solution Approach 2:
The single printed circuit board serves multiple functions: it provides electrical connectivity through conductive tracks, structural support, thermal management pathways, and mechanical flexibility through the deformation zone. This multi-functionality reduces the number of separate components needed, thereby lowering production costs while achieving thermal isolation.
3Reliability
If lighting elements and electronic driver are mounted on opposite sides of circuit board, then electrical contact is achieved, but manufacturing expenditure increases due to double-sided component provision
Solution Approach 1:
Instead of mounting components on opposite sides of the circuit board in three-dimensional space, the patent positions both the lighting elements and electronic driver on the same side of the board, separated by the deformation zone. This two-dimensional arrangement simplifies manufacturing by allowing all components to be mounted from one side, reducing assembly complexity and cost while maintaining reliable electrical contact through the conductive tracks in the deformation zone.
4Device complexity
If lighting elements and electronic driver are mounted on common circuit board, then number of parts is reduced, but thermal coupling between components increases
Solution Approach 1:
The deformation zone has locally different properties compared to the rest of the circuit board: it features reduced copper trace width or interrupted conductive paths that increase thermal resistance. This local modification allows the board to maintain electrical connectivity while creating a thermal barrier between the lighting elements and electronic driver, thus reducing thermal coupling in the critical interface region.
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 results in a light fixture with a simplified construction, reduced thermal coupling between components, lower production costs, and improved thermal isolation, enabling efficient heat management and compact design without the need for complex cooling systems.
Implementation Method 1
the first region and the second region are at least partially thermally isolated from one another by means of the connection zone
Implementation Method 2
the first region and the second region are electrically contacted with one another by means of the deformation zone
Data Source
AI summary
A light fixture includes a printed circuit board received in a housing. At least one light-emitting diode is mounted on a first region of the printed circuit board and an electronic driver is mounted on a second region of the printed circuit board. The first region is connected to the second region by a deformation zone of the printed circuit board formed in one-piece with the first region and the second region. The first region and the second region are electrically contacted with one another through the deformation zone.