Flexible Printed Circuit Light Engine for Neon Simulation
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Solution Overview
Problem
LED light assemblies used to simulate neon lighting face challenges such as cumbersome replacement of failed LEDs due to interconnected electrical connectors and rigidity, which limits shape alteration by consumers.
Innovation Solution
Incorporating a combination of insulation displacement connectors (IDCs) and support connectors within the light engine, along with a flexible printed circuit (FPC) to form a parallel circuit, allowing for shape flexibility and reduced stress on electrical connectors, thereby preventing complete light engine failure and enabling consumers to alter the assembly shape without replacing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation displacement connectors (IDCs) are used in the light engine, then reliability is improved by preventing cascading electrical connector failures, but device complexity and manufacturing cost increase
Solution Approach 1:
The light engine is divided into multiple independent electrical connector modules (IDCs and support connectors) that can function independently. Each connector is a separate unit that can be individually replaced without affecting the entire light engine system, thus improving reliability while maintaining manageable complexity through modular design.
Solution Approach 2:
Different types of electrical connectors (IDCs and support connectors) are strategically placed at different locations within the light engine based on specific functional requirements. IDCs provide robust electrical connection at critical points, while support connectors provide additional redundancy, creating local optimization of connector quality and reliability.
2Manufacturing precision
If a rigid printed circuit board (PCB) is used in the light engine, then manufacturing precision is improved, but adaptability deteriorates as consumers cannot alter the shape of the light assembly
Solution Approach 1:
The light engine transitions from a static, rigid PCB structure to a dynamic, flexible configuration using FPCB. The FPCB can be bent, folded, or contoured into different shapes while maintaining electrical connectivity, allowing the light assembly to adapt to various consumer needs and applications without sacrificing manufacturing precision.
Solution Approach 2:
The physical state of the circuit board is changed from rigid (PCB) to flexible (FPCB), altering the mechanical properties while maintaining electrical functionality. This parameter change enables the light assembly to be shaped into different configurations while preserving the precision of electrical connections through controlled flexibility.
3Strength
If the light engine is made rigid to maintain structural integrity, then strength is improved, but ease of operation deteriorates as consumers cannot reshape the assembly
Solution Approach 1:
The light engine utilizes flexible printed circuit boards (FPCB) that function as flexible structural elements. These thin, flexible circuits maintain sufficient mechanical strength to support electrical connections and LED components while allowing the overall assembly to be bent, folded, or contoured into different shapes by consumers without breaking or damaging structural integrity.
4Ease of manufacture
If all electrical connectors are replaced with support connectors to reduce cost, then manufacturing cost is reduced, but reliability deteriorates as the parallel circuit protection is lost
Solution Approach 1:
The electrical connector system is segmented into two types: IDCs at critical positions providing robust, redundant connections for reliability, and support connectors at other positions providing cost-effective connectivity. This segmentation allows the system to achieve reliability where needed while reducing overall manufacturing costs through selective use of connector types.
Solution Approach 2:
Different connector qualities are applied locally based on functional requirements. IDCs with higher reliability are placed at critical electrical connection points where failure would impact the entire system, while support connectors with lower cost are used at less critical positions, optimizing the balance between reliability and manufacturing cost.
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 reduces the cost of manufacturing and maintenance, enhances the flexibility of LED light assemblies, and decreases the likelihood of electrical component failure during shape changes, ensuring continuous functionality even if one IDC is compromised.
Implementation Method 1
the electrical connectors are joined using a flexible printed circuit (FPC). The FPC assists in allowing the light engine to be contoured into different shapes
Implementation Method 2
a light engine containing LEDs
Implementation Method 3
LED light assemblies have been used to simulate neon light
Data Source
AI summary
A system for simulating neon light comprising an elongated guide containing outer surface and a channel; a housing containing an engagement member and area for receiving a light engine; and the light engine. The light engine comprising a flexible printed circuit (FPC), a plurality of light emitting diodes (LEDs) attached to the FPC, and a plurality of electrical connectors all in contact with a power conductor. The FPC also includes a gathering of material between each of the plurality of electrical connectors. Also included is a method for reducing the stress within the light engine.