Flexible LED Light Housing with Variable Thickness
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Solution Overview
Problem
Flexible LED linear lights suffer from dark zones and 'hot spots' due to their unidirectional light emission, making it difficult to achieve uniform light transmission and posing challenges in manufacturing and aesthetics, particularly with existing diffusion methods and end cap mounting processes.
Innovation Solution
A flexible LED linear light assembly with a translucent housing that varies in thickness to optimize light transmission, combined with a method of manufacturing that includes an internal air or silicone gel gap to scatter light evenly, and end caps designed for flush mounting to enhance aesthetics and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid housing is used to enclose the LED linear light component, then structural stability is improved, but flexibility and adaptability deteriorate
Solution Approach 1:
The patent employs a flexible housing constructed from elastomeric or polymeric materials that can bend and conform to various shapes while maintaining structural integrity. This flexible housing encloses the LED linear light component and allows the assembly to be routed through confined spaces, mounted on irregular surfaces, or integrated into diverse decorative applications, thereby resolving the contradiction between structural stability and flexibility.
2Ease of manufacture
If uniform thickness housing is used, then manufacturing simplicity is improved, but light transmission uniformity deteriorates
Solution Approach 1:
The housing is designed with non-uniform thickness distribution, where the wall thickness varies at different locations along the housing length. Specifically, the housing includes a first section with a first average wall thickness and a second section with a second average wall thickness, allowing optimization of light transmission characteristics in different zones. This local variation in thickness compensates for positional variations in LED output intensity, achieving uniform overall light transmission while remaining manufacturable through techniques like injection molding.
3Illumination intensity
If existing diffusion methods are used, then light scattering is improved, but manufacturing complexity and aesthetic quality deteriorate
Solution Approach 1:
The patent integrates the light diffusion function directly into the housing structure itself, eliminating the need for separate diffusion components. The housing walls are designed with specific optical properties and thickness variations that inherently scatter and diffuse light as it passes through the housing material. This merging of the housing and diffusion functions simplifies the overall assembly, reduces manufacturing steps, and improves aesthetic quality by creating a smoother, more integrated appearance.
4Ease of operation
If end caps are mounted externally, then assembly ease is improved, but aesthetic quality deteriorates due to visible interfaces
Solution Approach 1:
The end caps are designed to nest within the housing structure rather than mounting externally. The housing includes recesses or integrated mounting features that allow the end caps to be positioned flush with or embedded in the housing ends. This nesting approach eliminates visible interfaces and step differences between the housing and end caps, creating a seamless, aesthetically pleasing appearance while maintaining ease of assembly through integrated mounting features.
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 effectively eliminates dark zones and hot spots, achieving uniform light distribution and improving the manufacturing process and aesthetics by ensuring even light transmission and smooth interfaces.
Implementation Method 1
a translucent housing or lens which has an elongated configuration for laterally enclosing the flexible LED linear light component... The translucent housing can include a housing wall having a first thickness from an interior apex located on an inner surface of the translucent housing... The housing wall of the translucent section decreases in thickness as the angle formed by the plane of the LEDs
Data Source
AI summary
A diffused flexible LED linear light assembly (100) includes a flexible LED linear light component (102) having a flexible base (104) with individual LEDs (106) spaced longitudinally along the direction of the component (102). A partially translucent housing (120) houses the flexible LED linear light component (102). A curved section (124) of the translucent housing (120) varies in thickness in its lateral surfaces. The thickness may be varied so as to allow a relatively higher percentage of light transmission in areas of weakest LED output strengths. This light output intensity through the translucent housing, in view of the thickness variation, is substantially even or constant circumferentially and radially through the translucent section (124) of the translucent housing (120).