Flexible LED Illumination Device with Modular Cut-and-Reconnect Design
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Solution Overview
Problem
Existing flexible LED illumination devices face challenges such as skidding during assembly, rigidity that prevents on-site bending, and the inability to be cut to match specific design parameters, along with complex electrical reconnection and installation difficulties.
Innovation Solution
A flexible LED illumination device featuring a translucent positioning strip with slots, light modules mounted on a circuit board, a power terminal, and a quintet of power conductors for easy electrical connection, along with an elongated light diffuser tube and potting glue for protection, allowing for easy bending and cutting to fit various designs, and an exposed power conductor for straightforward reconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If LED assemblies are inserted into the light guide during bending, then the illumination device can be shaped, but the assemblies skid due to tension
Solution Approach 1:
The patent performs the bending and shaping of the light guide before inserting the LED assemblies. By pre-forming the flexible circuit board and light guide into the desired shape, then inserting the LED assemblies into channels, the assemblies are positioned while the structure is stable, preventing skidding during the critical insertion phase
2Strength
If the light guide is made rigid for structural strength, then it can support the lighting elements, but it requires extreme heat to bend and cannot be bent on-site
Solution Approach 1:
The patent employs a flexible circuit board as the light guide structure, which inherently provides both structural integrity to support LED assemblies and light elements, and flexibility to be bent into various shapes. The flexible substrate allows on-site installation and customization without requiring extreme heating processes
3Stability of the object's composition
If the illumination device is designed as a complete unit, then it maintains structural integrity, but it cannot be cut to match building features or design parameters
Solution Approach 1:
The patent designs the illumination device as a modular system where the flexible circuit board can be cut into segments at predetermined locations. Each segment maintains its structural integrity with integrated LED assemblies, while allowing customization to match specific building features or design requirements. The modular nature enables both structural stability and adaptability
4Ease of repair
If mounting pads are used to reconnect electrical coupling after cutting, then electrical connection can be restored, but a particular connector is vital and reconnection becomes complex
Solution Approach 1:
The patent incorporates universal electrical connection mechanisms that work across all segments and configurations. The flexible circuit board includes integrated conductive traces and contact points that provide standardized, simple reconnection methods regardless of where the device is cut or how it is configured, eliminating the need for specialized connectors
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 customizable LED lighting that can be easily cut and reconnected, providing a safer, more controllable, and cost-effective solution for simulating neon signs with improved assembly and installation processes.
Implementation Method 1
an elongated light diffuser tube disposed at the top of the translucent housing, and wherein said elongated light diffuser tube being configured to diffused light from the plurality of LEDs simulating a neon sign
Data Source
AI summary
A Flexible LED illumination device, according to the present invention, comprises a translucent positioning strip having a plurality of slots disposed at the center, a plurality of light modules mounted inside of the translucent positioning strip, a plurality of power conductors in communication to the plurality of light modules, a translucent housing covering the plurality of light modules, an elongated light diffuser tube disposed at the top of the translucent housing, and wherein said elongated light diffuser tube is configured to refract light from the plurality of light modules, a potting glue disposed at the bottom of the plurality of power conductors, and exposed power conductors extruding in between the plurality of light modules. The flexible LED illumination device is constructed with flexible material to allow bending to any shapes, and weatherproofing.