Flexible LED Circuit Boards for Custom Light Distribution
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Solution Overview
Problem
Conventional lighting fixtures with fixed LED arrays cannot provide customizable light distribution patterns, limiting their adaptability to various applications.
Innovation Solution
The use of flexible LED circuit boards with reflective substrates, such as PET, that can be shaped to conform to custom forms or woven between rods, allowing for adjustable LED placements and light distribution patterns using the same physical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional fixed LED arrays are used, then manufacturing is simple, but light distribution cannot be customized
Solution Approach 1:
The patent applies the dynamics principle by making the LED circuit board flexible rather than rigid, allowing it to be bent and shaped into different configurations. This flexibility enables the same physical parts to produce various light distribution patterns by simply changing the shape of the flexible board, thereby achieving customizability without requiring multiple different LED array designs.
Solution Approach 2:
The patent utilizes parameter changes by altering the geometric parameters (shape, curvature, folding pattern) of the flexible LED circuit board to achieve different light distribution patterns. By changing these physical parameters of the board's configuration rather than changing the LED components themselves, the system achieves versatility while maintaining manufacturing simplicity.
2Adaptability or versatility
If flexible LED circuit boards are shaped to conform to custom forms, then light distribution becomes customizable, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the flexible LED circuit board into modular segments or sections that can be independently shaped and configured. This segmentation allows for easier manufacturing and assembly while achieving custom forms, as each segment can be produced with standard precision and then assembled into the desired overall configuration through folding, bending, or modular assembly.
3Adaptability or versatility
If LED spacing is adjusted to change light distribution, then light delivery becomes customizable, but device complexity increases
Solution Approach 1:
The patent applies dynamics by making the LED spacing adjustable through the flexibility of the circuit board itself. Rather than manufacturing different LED arrays with varying spacing, the same LED array can be positioned at different spacings by bending or folding the flexible board, allowing custom light delivery patterns to be achieved dynamically during installation rather than through complex manufacturing variations.
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 customizable light delivery with reduced production costs and no need for heat sinks, as the flexible boards can provide both directed and diffused light sources based on their shape and LED spacing.
Implementation Method 1
The flexible LED circuit boards include an array of LED packages or LED chips
Implementation Method 2
the surface of the flexible circuit boards is highly reflective
Data Source
AI summary
Techniques are disclosed for designing light fixtures for flexible LED circuit boards. The flexible LED circuit boards include an array of LED packages and the surface of the flexible circuit boards is highly reflective. A flexible LED circuit board may be shaped to conform to a rigid preform and the preform may be concave, convex, corrugated, or have any other custom shape. The shape of the preform, as well as the location of the LEDs within the flexible LED circuit may determine the light distribution of the light fixture. Alternatively, the lighting fixture may have multiple rods held in place with side plates and a flexible LED circuit board may be woven between the rods. A set of hole patterns in the side plates determine the location of the rods and the rods will determine the shape of the flexible LED circuit.