Flexible LED Strip Interposer Layout for Precise Positioning
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Solution Overview
Problem
The accurate positioning of light-emitting diodes on electrical conductors in flexible LED bands is complex due to their length and stress, making it difficult to achieve reliable connections for automotive applications.
Innovation Solution
A method for producing a flexible lighting strip with light-emitting diodes arranged in a longitudinal configuration using wire segments with circular cross-sections that can absorb compressive and tensile stress, allowing for precise soldering and mechanical symmetry, and potentially using interposers with light-emitting diodes mounted on them, connected via laser welding or other welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If light-emitting diodes are positioned directly on long electrical conductors, then the lighting strip can be produced, but the positioning accuracy deteriorates due to conductor length and stress
Solution Approach 1:
The patent divides the continuous electrical conductor into discrete conductor sections, each associated with a specific light-emitting diode or group of diodes. This segmentation allows each section to be precisely positioned and soldered independently, eliminating the cumulative positioning errors that occur with long continuous conductors. The conductor sections are arranged in a comb-like pattern that facilitates accurate alignment during the molding process.
Solution Approach 2:
The patent introduces a comb-like structure as an intermediary element that holds both the conductor sections and light-emitting diodes in predetermined positions. This comb structure acts as a positioning template or fixture during assembly, ensuring that conductors and diodes align accurately without requiring complex manual positioning procedures. The comb structure is integrated into the mold, making it a permanent part of the lighting strip assembly.
2Reliability
If conventional conductor arrangements are used, then the structure is simple, but the reliability deteriorates under thermomechanical stress
Solution Approach 1:
The patent introduces flexible zones in the conductor arrangement that can dynamically adapt to thermomechanical stresses. These flexible zones allow the conductor structure to deform elastically under stress rather than fracturing, maintaining electrical connectivity during thermal cycling and mechanical bending. The comb-like structure inherently provides this flexibility through its geometric configuration, allowing controlled movement while maintaining structural integrity.
3Ease of manufacture
If asymmetric conductor arrangements are used, then positioning may be simplified, but mechanical symmetry and stress distribution deteriorate
Solution Approach 1:
The patent employs asymmetric conductor sections within the symmetric comb structure, where individual conductor segments have different lengths or configurations optimized for their specific positioning tasks. This controlled asymmetry allows each conductor section to be precisely tailored for its function while the overall comb structure maintains mechanical symmetry for balanced stress distribution. The asymmetric positioning elements are integrated into the symmetric mold design, combining both advantages.
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 enables high-accuracy positioning and improved reliability of light-emitting diodes, allowing the flexible lighting strip to withstand thermomechanical stress tests and meet automotive application requirements.
Implementation Method 1
at least one of the wire segments of the outer lines is bent building zones that are capable to receive compressive and/or tensile stress
Implementation Method 2
The method comprises the steps of soldering a first functional element to a first wire segment and connecting of the at least one wire segment to a second functional element
Implementation Method 3
The at least one wire segment is connected to the second wire segment by laser welding
Data Source
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AI summary
The invention describes a method for producing a flexible lighting strip (100) comprising a multitude of functional elements (21) in a longitudinal arrangement. The functional elements (21) comprise light-emitting diodes (22). In one alternative, the functional elements (21) may be light-emitting diodes (22) itself. In another alternative, the functional elements (21) may be interposers (24) with light-emitting diodes (22) mounted thereon. The functional elements (21) are arranged in at least two groups. Each group comprises at least two functional elements (21) arranged in an electrical series connection. The at least two groups are arranged in an electrical circuit having at least an anode track (12) and a cathode track (14) as outer lines (12, 14), wherein the at least two functional elements (21) are arranged in an electrical parallel connection to the anode track (12) and the cathode track (14). The at least two groups are arranged in a longitudinal arrangement such that a last functional element (21) of a first group is arranged next to a first functional element (21) of a second group. Each of the outer lines (12, 14) consists of a wire line having substantially circular wires (30), whereby the wires (30) of the outer lines (12, 14) are bent building zones that are capable to receive compressive and/or tensile stress. The electrical circuit provides a third wire line (15) having a substantially circular wire (30) as a center line arranged between the outer lines (12, 14). The method comprises the steps of soldering a first functional element (21) to a first wire segment and connecting of the at least one wire segment to a second functional element.