Flexible LED Light Engine with IDC Terminal and Heat Sink
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Solution Overview
Problem
Existing LED lighting systems face issues with heat dissipation, mechanical and electrical failures, limited flexibility, and non-user serviceable designs, particularly when attempting to replace neon or fluorescent lighting.
Innovation Solution
A flexible LED light engine featuring a heat sink, IDC terminal, and PCB, where the flexible power cord includes an insulating material and an electrical wire, allowing for easy attachment and replacement of LED modules without exposing conductor wires, and providing effective heat dissipation without requiring a conductive mounting surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are mounted on printed circuit boards connected by electrical jumpers, then electrical connection is achieved, but the system becomes susceptible to mechanical and electrical failures due to external forces or poor installation techniques
Solution Approach 1:
The system divides the lighting installation into modular LED units that can be independently handled and installed. Each LED unit contains its own mounting features and electrical connections, allowing for simplified installation without complex jumper connections between separate components.
Solution Approach 2:
The patent combines multiple functions into the LED unit itself: the LED, its electrical connections, mounting features, and heat dissipation elements are integrated into a single modular component, eliminating the need for separate mounting structures and electrical jumpers.
2Temperature
If high-power LED products require mounting to conductive surfaces to dissipate heat, then heat dissipation is achieved, but the system loses flexibility and requires conductive mounting surfaces
Solution Approach 1:
The patent introduces a heat dissipation element as an intermediary component that couples the LED to the mounting surface. This element provides the thermal conduction path without requiring the mounting surface itself to be conductive, allowing installation on non-conductive surfaces while maintaining effective heat dissipation.
Solution Approach 2:
The heat dissipation function is localized to specific elements within the LED unit rather than requiring the entire mounting surface to have thermal conduction properties. The heat dissipation element is positioned directly at the LED-to-surface interface where thermal transfer is most critical.
3Ease of repair
If conventional LED lighting systems are used, then lighting function is achieved, but they are not user serviceable to replace individual LEDs or LED modules
Solution Approach 1:
The lighting system is divided into replaceable LED modules that can be independently serviced. Each module contains a complete LED unit with its own electrical connections and mounting features, allowing users to replace individual modules without disassembling the entire lighting system or dealing with complex wiring.
Solution Approach 2:
The LED units are designed with dynamic installation and removal capabilities through features like push-button release mechanisms or snap-fit connections. This allows the system to transition from a fixed, non-serviceable state to a easily reconfigurable state for maintenance and replacement.
4Adaptability or versatility
If LEDs are mechanically affixed to flexible electrical cords, then flexibility is achieved, but the system has limited lineal resolution and structural stability
Solution Approach 1:
The LED units are pre-assembled with integrated mounting features and electrical connections before installation. This preliminary assembly ensures proper structural alignment and electrical connectivity, allowing for flexible installation configurations while maintaining structural stability without requiring complex on-site assembly procedures.
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
The solution enhances flexibility, improves heat management, and allows for easy maintenance by enabling the replacement of individual LED modules without exposing electrical connections, thereby reducing mechanical and electrical failures and increasing the system's reliability and usability.
Implementation Method 1
The second surface is abutted against a surface of the heat sink so that heat is transferred from the LED into the heat sink
Data Source
AI summary
A string light engine includes a flexible power cord, a heat sink, an IDC terminal, a PCB, and an LED. The flexible power cord includes an electrical wire and an insulating material for the wire. The heat sink attaches to the power cord. The IDC terminal is inserted through the insulating material and electrically communicates with the wire. The PCB is at least partially received in the heat sink. The PCB includes a first surface having circuitry and a second surface opposite the first surface. The circuitry is in electrical communication with the IDC terminal. The second surface is abutted against a surface of the heat sink so that heat is transferred from the LED into the heat sink. The LED mounts to the first surface of the PCB and is in electrical communication with the circuitry.