Flexible LED Module Angled Substrate Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional linear LED modules are expensive, heavy, and overly complex due to their use of rigid substrates and metal reflectors, making them difficult to design as cost-efficient and lightweight alternatives for troffer assemblies.
Innovation Solution
A linear LED module utilizing a flexible substrate with angled portions that replaces the need for a rigid substrate and metal reflector, allowing for customizable bending and integration of reflective and diffusive layers to achieve directed light distribution without the complexity and cost of traditional designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid substrates and metal reflectors are used in conventional linear LED modules, then structural stability and light reflection are improved, but device complexity, weight, and cost increase
Solution Approach 1:
The patent combines the substrate and reflector into a single integrated flexible PCB structure. The reflective surface is formed directly on the flexible substrate through metallization layers, eliminating the need for separate metal reflector components. This merging reduces device complexity while maintaining structural stability and light reflection functionality.
Solution Approach 2:
The flexible PCB substrate serves multiple functions simultaneously: it provides structural support, acts as a mounting platform for LED components, conducts electrical signals, and functions as a reflector through its metallized surface. This multi-functionality reduces the number of separate components needed, thereby reducing overall device complexity.
2Reliability
If rigid substrates and metal reflectors are used in conventional linear LED modules, then structural stability is improved, but weight increases
Solution Approach 1:
The patent employs a flexible PCB substrate that is significantly thinner and lighter than conventional rigid substrates. The flexible nature of the substrate allows it to maintain structural integrity while reducing mass. The metallized reflective surface is applied as a thin film layer, further minimizing weight while providing effective light reflection.
3Illumination intensity
If rigid substrates and metal reflectors are used in conventional linear LED modules, then light reflection is improved, but cost increases
Solution Approach 1:
By integrating the reflector function directly into the flexible PCB substrate through metallization processes, the patent eliminates the need for separate metal reflector components. This reduces the number of parts that need to be manufactured, stocked, and assembled, thereby lowering manufacturing costs while maintaining effective light reflection.
Solution Approach 2:
The patent changes the physical state and form of the reflective surface from a separate metal component to a metallized layer on a flexible substrate. This parameter change allows for more cost-effective manufacturing through standard PCB fabrication processes, reducing overall production costs while maintaining optical performance.
4Reliability
If conventional linear LED module designs are used, then light distribution efficacy is maintained, but adaptability and customization options are reduced
Solution Approach 1:
The flexible PCB substrate can be bent, folded, and shaped into various configurations to adapt to different troffer designs and lighting requirements. This dynamic flexibility allows for customization of the module shape and light distribution patterns while maintaining effective light reflection and distribution efficacy.
Solution Approach 2:
The flexible nature of the PCB substrate enables it to be conformally mounted to different surfaces and configurations within troffer assemblies. This flexibility provides design adaptability and customization options for different application requirements while maintaining the same light distribution performance as rigid designs.
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 flexible substrate design reduces complexity and cost while maintaining the same light distribution efficacy as conventional modules, offering a lightweight and customizable solution for troffer assemblies.
Implementation Method 1
The flexible substrate includes a reflective portion and a diffusive portion
Implementation Method 2
The flexible substrate includes a reflective portion and a diffusive portion
Data Source
AI summary
Various aspects of a light emitting apparatus include a substrate having at least one angled portion. Some aspects of the light emitting apparatus include at least one light emitting device arranged on the substrate. Some aspects of the light emitting apparatus include a plurality of conductors arranged on the substrate. In some aspects of the light emitting apparatus, the conductors are electrically coupled to the at least one light emitting device.