Flexible LED Lighting with Adhesive Strap Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost and environmental concerns associated with using polyamide or polyimide substrates and print-and-etch processes for LED lighting arrangements on flexible substrates, due to expensive chemicals and hazardous waste generation, necessitate a more cost-effective and environmentally friendly solution.
Innovation Solution
The use of a flexible substrate with adhesive-attached straps having exposed terminals for mounting LEDs, allowing for visible and accessible electrical connections, simplifying the wiring process by laying wires over the straps and attaching them with pressure-sensitive adhesive or low-temperature soldering, reducing the need for complex and expensive print-and-etch techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyamide or polyimide substrates with print-and-etch processes are used for LED mounting, then reliable electrical connections and durable flexible substrate performance are achieved, but manufacturing cost increases and environmental harm occurs due to expensive chemicals and hazardous waste
Solution Approach 1:
The patent extracts the harmful print-and-etch process from the manufacturing system and replaces it with direct wire attachment to LED leads. This eliminates the need for expensive chemicals and hazardous waste generation while maintaining reliable electrical connections through direct metal-to-metal contact between wires and LED terminals
Solution Approach 2:
The patent replaces expensive polyamide or polyimide substrates with inexpensive flexible materials such as polyester or vinyl. The substrate serves its primary function of providing flexibility and mechanical support without requiring the high-performance characteristics of expensive materials, thus reducing cost and environmental impact
2Reliability
If polyamide or polyimide substrates with print-and-etch processes are used for LED mounting, then reliable electrical connections are achieved, but manufacturing cost increases due to expensive chemicals and complex processes
Solution Approach 1:
The patent removes the expensive print-and-etch manufacturing step and replaces it with simple wire attachment to LED leads. This eliminates the need for expensive chemicals and complex process equipment while maintaining reliable electrical connections through direct wiring
Solution Approach 2:
The patent substitutes costly polyamide or polyimide substrates with inexpensive flexible materials like polyester or vinyl. This replacement maintains the necessary flexibility and mechanical properties while dramatically reducing material costs
3Manufacturing precision
If wires are attached to substrate before LED placement, then wiring pattern precision is maintained, but wiring complexity and manufacturing difficulty increase
Solution Approach 1:
The patent inverts the traditional wiring sequence by attaching wires to LED leads first, then mounting the LED assemblies onto the flexible substrate. This reversal eliminates the need for complex pre-printed wiring patterns on the substrate, as wires are directly connected to LED terminals regardless of position, thereby reducing wiring complexity while maintaining connection precision
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 approach significantly reduces manufacturing costs and environmental impact by allowing the use of inexpensive substrates and simplifying the wiring process, while enabling flexible and efficient LED lighting arrangements suitable for various applications, including large-scale graphics.
Implementation Method 1
Each strap of a plurality of straps has a first surface, a second surface, and first and second terminals exposed on the first surface. The second surface of each strap is attached to the first surface of the flexible substrate by the adhesive.
Data Source
AI summary
An LED lighting arrangement on a flexible substrate. The flexible substrate has an adhesive on a first surface. Straps are attached to the first surface of the flexible substrate by the adhesive. Each strap has a first surface, a second surface, and first and second terminals exposed on the first surface. The attachment of each strap to the substrate is with the second surface of the strap adhered to the substrate. LEDs are attached to the straps and coupled to the terminals on the straps. An arrangement of one or more wires is attached to the first surface of the flexible substrate by the adhesive. The wires are connected to the first and second terminals on the first surfaces of the plurality of straps to provide power to the LEDs.