Flexible LED Light Element for Curved Vehicle Surfaces
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Solution Overview
Problem
Existing lighting systems in vehicles face limitations in replicating complex structures, require large circuit boards, are space-intensive, and have limited dynamic effects, making them unsuitable for curved surfaces and radar applications.
Innovation Solution
A light element comprising a series of LEDs enclosed in a flexible housing and covered by a translucent plastic cover, which emits light without a beam-shaping optical element, allowing for flexible arrangement and dynamic effects, and can be manufactured in unlimited lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If fiber optic cables are used for lighting, then light can be transmitted over distances, but the length is limited and minimum radii of curvature are large
Solution Approach 1:
The lighting system is divided into multiple independent LED modules that can be individually positioned and oriented. Each LED acts as an independent light source, eliminating the need for continuous light transmission through fiber optics. This segmentation allows the lighting to conform to complex shapes and tight curves without the physical constraints of fiber optic cables.
Solution Approach 2:
The mechanical fiber optic cable system is replaced with electronic LED modules connected through circuitry. This substitution eliminates the physical flexibility constraints of fiber optics, allowing the lighting to be arranged in complex three-dimensional configurations with small radii of curvature while maintaining design flexibility.
2Illumination intensity
If backlit diffuser discs are used, then lighting can be achieved, but large circuit board area is required and the structure is space-intensive
Solution Approach 1:
The lighting design transitions from a two-dimensional diffuser disc approach to a three-dimensional arrangement of LED modules. LEDs can be mounted on various surfaces including curved planes, edges, and vertical structures, utilizing spatial volume rather than requiring extensive flat circuit board area. This dimensional transition enables lighting in space-constrained environments.
Solution Approach 2:
The patent employs flexible PCB substrates and thin-film mounting techniques that allow LED arrays to be conformally mounted on curved and irregular surfaces. This eliminates the need for large rigid circuit boards while maintaining electrical connectivity and lighting output, enabling integration into compact vehicle interior spaces.
3Illumination intensity
If conventional lighting systems are used, then lighting function is achieved, but dynamic effects and animations are not practically feasible
Solution Approach 1:
The static lighting system is transformed into a dynamic one by implementing independent control of multiple LED modules through microcontroller units. Each LED or group of LEDs can be individually addressed and controlled, enabling dynamic effects such as sequential lighting, color transitions, patterns, and animations. This dynamic control capability allows the lighting to adapt to different driving conditions, moods, and user preferences.
Solution Approach 2:
The LED-based lighting system is designed to perform multiple functions beyond simple illumination, including dynamic animations, color coding for different driving modes, integration with vehicle sensors for adaptive lighting, and communication functions. This multi-functionality is achieved through programmable control of the LED modules, making the system adaptable to various applications and enhancing overall vehicle functionality.
4Illumination intensity
If LED light strips with circuit boards are used, then lighting can be provided, but the structure is rigid and difficult to attach to curved surfaces
Solution Approach 1:
The rigid circuit board structure is replaced with flexible PCB substrates and thin-film mounting techniques that allow the LED arrays to be conformally mounted on curved and irregular surfaces. The flexible substrates can be bent, shaped, and attached to complex geometries while maintaining electrical connectivity, enabling integration into vehicle interiors with curved panels and three-dimensional features.
Solution Approach 2:
The physical parameters of the substrate material are changed from rigid to flexible, allowing the lighting structure to adapt to various mounting surfaces. This parameter change enables the lighting to be installed on curved, angled, and irregular surfaces without requiring complex mechanical adaptation or compromising the structural integrity of the installation.
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 complex lighting designs, robustness against mechanical damage, and versatile applications, including radar compatibility, with homogeneous luminance and dynamic effects without additional optical elements.
Implementation Method 1
The cover is made of a translucent plastic material and is intended for at least substantially homogeneous diffuse scattering of the light emitted by the LEDs
Data Source
Figure 1~4
Figure 5~6
Figure 7~8
AI summary
The invention relates to a lighting element (1) for a motor vehicle (18) and a correspondingly equipped motor vehicle (18). The lighting element (1) comprises a series of adjacent LEDs (4, 5) and a flexible cover (3) which covers the LEDs (4, 5) at least on their light-emitting side (11) without the use of a beam-shaping optical element. The lighting element (1) has an elongated housing (2) open on one longitudinal side (7), which is made of a flexible plastic material and in which the series of LEDs (4, 5) are received with their light-emitting side (11) facing the open longitudinal side (7). The cover (3) closes the open longitudinal side (7) of the housing (2) and is made of a translucent plastic material for at least substantially homogeneous diffuse scattering of the light emitted by the LEDs (5).