3D Flexible LED Bar with Segmented PCB for Multi-Axis Bending

Solution Overview

Problem

Conventional LED lighting designs lack multi-axis flexibility, limiting their application in complex aesthetic and contour lighting scenarios where bending and twisting are required, as they can only flex along a single axis, necessitating additional complexity and expense in design and manufacturing.

Innovation Solution

A 3-D flexible PCB strip with alternating wide and narrow segments, allowing for multi-axis bending and twisting, where LEDs can be mounted on wide segments and the narrow segments facilitate flexibility in multiple directions, enabling pre-shaping into various shapes and protection with silicon molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional flexible LED strips are designed to bend along a single axis, then they can be manufactured simply and mounted easily, but they cannot conform to complex curves and corners requiring multi-axis flexibility

Engineering Contradiction:

ImproveflexibilityVSAvoiddesign complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The PCB strip is divided into alternating wide segments and narrow segments. The narrow segments act as hinges that enable bending, while the wide segments provide mounting surfaces for LEDs and maintain structural integrity. This segmentation allows the strip to flex along multiple axes without requiring complex overall design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different segments of the PCB strip have different widths to provide different functions. The narrow segments are designed specifically for flexibility and bending, while the wide segments are designed for component mounting and structural support. This local differentiation of properties enables multi-axis flexibility without compromising the overall structural integrity or requiring complex design throughout the entire strip.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If conventional LED strips are made rigid to maintain component alignment, then structural integrity is maintained, but they cannot be bent or twisted to follow complex contours

Engineering Contradiction:

ImproveflexibilityVSAvoidcomponent alignment

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The PCB strip is divided into alternating wide segments and narrow segments. The narrow segments act as hinges that enable bending, while the wide segments provide mounting surfaces for LEDs and maintain structural integrity. This segmentation allows the strip to flex along multiple axes without requiring complex overall design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different segments of the PCB strip have different widths to provide different functions. The narrow segments are designed specifically for flexibility and bending, while the wide segments are designed for component mounting and structural support. This local differentiation of properties enables multi-axis flexibility without compromising the overall structural integrity or requiring complex design throughout the entire strip.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If additional electronics and wiring are added to achieve multi-axis flexibility, then the LED strip can conform to complex shapes, but manufacturing cost and complexity increase significantly

Engineering Contradiction:

ImproveflexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The PCB strip is divided into alternating wide segments and narrow segments. The narrow segments act as hinges that enable bending, while the wide segments provide mounting surfaces for LEDs and maintain structural integrity. This segmentation allows the strip to flex along multiple axes without requiring complex overall design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different segments of the PCB strip have different widths to provide different functions. The narrow segments are designed specifically for flexibility and bending, while the wide segments are designed for component mounting and structural support. This local differentiation of properties enables multi-axis flexibility without compromising the overall structural integrity or requiring complex design throughout the entire strip.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10222036B2Method and system for a three-dimensional (3-D) flexible light emitting diode (LED) bar

Publication Date: 2019.03.05 GE LIGHTING SOLUTIONS LLC

AI summary

Provided is a system for mounting electrical components thereon. The system includes an elongated printed circuit board (PCB) configured for coupling a plurality of electrical components thereto. The elongated PCB includes (i) one segment having a first width and (ii) another segment having a second width different than the first width. The other segment is bendable along multiple axes.