Flexible Electrical Coupling Device for Lighting Systems
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Solution Overview
Problem
High luminance flexible LED-based lighting systems lack flexibility and reliability.
Innovation Solution
An electrical coupling device comprising wires, spacers, and a flexible cover that allows for bending in all three dimensions, providing reliable electrical isolation and mechanical stability, with spacers and coupling spacers made from materials with high thermal conductivity and stiffness, and a heat dissipation structure for efficient cooling and data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid structures are used to provide stability and electrical isolation, then reliability and electrical isolation are improved, but flexibility and ability to bend are worsened
Solution Approach 1:
The patent uses a flexible cover made of rubber-like material (such as silicone rubber or poly siloxane rubber) with shore hardness varying from 20 to 80 shore A to embed and protect the wires and spacers. This flexible shell allows the electrical coupling device to bend in all three dimensions with a minimum radius of curvature of 10 mm while maintaining structural integrity and electrical isolation, directly resolving the contradiction between rigidity for reliability and flexibility for adaptability.
Solution Approach 2:
The patent combines materials with different properties: the flexible cover uses rubber-like material for flexibility, while the spacers and coupling spacers use materials with high thermal conductivity (more than 2 W/(mK), preferably more than 5 W/(mK) and most preferably more than 10 W/(mK)) and stiffness for structural stability. This composite material approach allows simultaneous achievement of flexibility and reliability.
2Stability of the object's composition
If spacers and coupling spacers are made stiff to provide stability, then mechanical stability is improved, but flexibility and stress absorption are worsened
Solution Approach 1:
The patent applies local quality by making different parts of the device have different mechanical properties. The spacers and coupling spacers are made stiff (with high thermal conductivity materials) to provide local structural stability and maintain wire spacing, while the flexible cover provides overall flexibility. The coupling spacer specifically is designed to reduce or absorb mechanical stress caused by bending, enabling reliable connection to functional elements while maintaining local stability where needed.
Solution Approach 2:
The patent changes the physical parameters of different components: the flexible cover has shore hardness varying from 20 to 80 shore A for flexibility, while the spacers and coupling spacers have high thermal conductivity (more than 2 W/(mK)) and stiffness. The coupling spacer is specifically designed with stress-absorbing characteristics to handle mechanical deformation, allowing the device to bend with a minimum radius of curvature of 10 mm while maintaining structural integrity.
3Volume of moving object
If wires are physically close to reduce device size, then compactness is improved, but electrical isolation and reliability are worsened
Solution Approach 1:
The patent introduces spacers and coupling spacers as intermediary elements between the first wire and the second wire. These spacers provide a defined distance between the wires, ensuring reliable electrical isolation while allowing compact arrangement. The spacers are embedded in the flexible cover, which further enhances electrical isolation by separating the wires from each other, thus achieving both compactness and reliable electrical isolation.
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
Enables flexible and reliable installation of lighting systems with improved mechanical stress absorption and heat dissipation, enhancing the reliability and luminance of high-power LED-based lighting systems.
Implementation Method 1
The flexible cover provides a reliable electrical isolation between the two wires by separating the wires from each other
Implementation Method 2
an electrically isolating material with a relatively high thermal conductivity of more than 2 W/(mK), more preferably more than 5 W/(mK) and most preferably more than 10 W/(mK)
Data Source
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AI summary
The invention relates to an electrical coupling device (110) for coupling functional elements (50) of a lighting system (200), wherein the electrical coupling device (110) comprises a first wire (11), a second wire (22), at least one spacer (20) and at least one coupling spacer (22). The at least one spacer (20) is arranged to provide a first defined distance between the first wire (11) and the second wire (12) at the position of the spacer (20). The coupling spacer (22) is arranged to provide a second defined distance between the first wire (11) and the second wire (12) at the position of the coupling spacer (22). The coupling spacer (22) is further arranged to electrically couple the functional element (50) to the electrically coupling device (110), wherein the at least one spacer (20) and the coupling spacer (22) are physically separated from each other, and wherein the at least one coupling spacer (22), the at least one spacer (20), the first wire (11) and the second wire (12) are embedded in a flexible cover (30). The coupling device (110) embedded in the flexible cover (30) enables flexibility in all three dimensions at a position between the at least one spacer (20) and the at least one coupling spacer (22). The invention further relates to a lighting system (200) comprising such an electrical coupling device (110) and a functional element (50).