Flexible LED Lighting with Arc-Shaped Notches for Spatial Curves
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Solution Overview
Problem
Existing LED lighting products with flexible waterproof shells face challenges in mounting reliability, particularly in spatial curve applications, and have limitations in bending and twisting capabilities, leading to potential functional failures and increased after-sales service issues due to restricted mounting behaviors.
Innovation Solution
The LED lighting solution features a flexible sleeve wrapping a FPCBA assembly with arc-shaped notches on the FPCB, welded leads for improved conductivity, and a secondary extrusion process for enhanced mechanical strength and light guiding, allowing for flexible bending and twisting in any direction, along with cuttable positions for customizable length and independent circuit power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional FPCBA light strip with fixed waterproof shell structure is used, then manufacturing process is simple, but mounting reliability in spatial curve applications is poor and functional failures occur
Solution Approach 1:
The FPCB is divided into multiple independent circuit segments separated by arc-shaped notches, allowing each segment to be independently mounted and adjusted. This segmentation enables the lighting strip to accommodate spatial curve applications without compromising electrical connectivity, thereby improving mounting reliability while maintaining manageable structural complexity through modular design
Solution Approach 2:
The lighting strip incorporates dynamic flexibility through the arc-shaped notches that allow the FPCB to be bent and twisted in any direction during installation. This dynamic capability enables adaptation to various spatial curve configurations while maintaining electrical connectivity, resolving the contradiction between reliability in complex applications and structural simplicity
2Adaptability or versatility
If single side bending or top bending plane curve application is used, then mounting behavior is restricted to certain directions, but product adaptability to different application scenes is limited
Solution Approach 1:
The arc-shaped notches are designed to enable the FPCB to be bent in multiple directions (side bending, top bending, and spatial curves), making the lighting strip universally applicable to various application scenes including linear, lateral, top, and spatial curve configurations. This multi-directional bending capability provides mounting adaptability while the standardized notch design keeps mounting operations simple and intuitive
Solution Approach 2:
The physical geometry of the FPCB is modified by introducing arc-shaped notches with specific curvature radii and spacing, which changes the bending parameters of the strip. These parameter changes enable the strip to achieve multi-directional bending while maintaining structural integrity and electrical connectivity, thereby improving adaptability without complicating the mounting process
3Length of stationary object
If LED lighting is made longer to cover larger areas, then application scale is increased, but brightness consistency and functional reliability deteriorate
Solution Approach 1:
The FPCB is segmented into multiple independent circuit sections by arc-shaped notches, allowing each section to be independently powered and controlled. This segmentation ensures that even in long lighting installations, each segment maintains consistent brightness and functionality, preventing the deterioration of reliability that would otherwise occur with longer single-section lighting strips
Solution Approach 2:
The arc-shaped notches act as intermediary structures that provide both mechanical flexibility and electrical isolation between circuit segments. These intermediaries enable the lighting strip to be made longer while maintaining brightness consistency by allowing controlled electrical separation and independent power distribution across segments
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
This design enhances mounting reliability, maintains consistent brightness over longer lengths, improves mechanical strength, and reduces light pollution, enabling flexible and reliable spatial curve applications with reduced risk of functional failures and simplified installation.
Implementation Method 1
The LED independent circuit comprises a plurality of LED luminous elements connected in series
Implementation Method 2
one lead is communicated with all positive electrode bonding pads in a welded mode and the other lead is communicated with all negative electrode bonding pads in a welded mode
Data Source
AI summary
Disclosed is a LED lighting capable of being bent and twisted at will, which comprises a flexible sleeve, a FPCBA assembly and a lead. The FPCBA assembly is formed by sequentially mounting multiple groups of LED independent circuits on a strip-shaped FPCB by a SMT, a plurality of arc-shaped notches are evenly arranged on long edges of two sides of the FPCB at intervals, a back surface of the FPCB is provided with a positive electrode bonding pad and a negative electrode bonding pad corresponding to each group of LED independent circuits respectively, two leads are provided, and are communicated with all positive electrode bonding pads and all negative electrode bonding pads in a welded mode respectively, and the flexible sleeve wraps and packages the FPCBA assembly and the leads.