Flexible LED Lamp PCB Heat Dissipation Assembly
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Solution Overview
Problem
Existing LED lamps face challenges with heat dissipation and lengthy assembly times due to complex wiring and electronic component connections, which restrict aesthetic design and reliability.
Innovation Solution
A low-consumption LED lamp design featuring a heat-dissipating supporting structure with a flexible, heat-conducting element and integrated circuitry on a single, flexible printed circuit, eliminating wires and providing capacitive luminous intensity regulation for reduced assembly time and enhanced aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring and electronic component connections are used in LED lamps, then reliable electrical connections are achieved, but assembly time increases and aesthetic design is restricted
Solution Approach 1:
The patent integrates multiple electronic components (LED modules, driver circuitry, control electronics) directly onto a single flexible printed circuit board (PCB). This merging eliminates the need for separate wiring harnesses and discrete component mounting, reducing assembly steps while maintaining reliable electrical connections through standardized PCB trace connections.
Solution Approach 2:
The invention employs a flexible PCB as the base structure that combines electrical connectivity with mechanical flexibility. This flexible circuit substrate allows the lamp to achieve complex aesthetic shapes while maintaining reliable electrical connections between all components without requiring traditional rigid wiring assemblies.
2Ease of operation
If complex wiring and electronic component connections are implemented, then functional requirements are met, but device complexity increases
Solution Approach 1:
Multiple functional components are merged into a single integrated assembly on the flexible PCB. The driver circuit, control electronics, and LED mounting structures are all integrated onto the same substrate, eliminating the need for separate wiring looms, connectors, and mounting brackets, thereby reducing overall device complexity.
Solution Approach 2:
The flexible PCB serves multiple functions simultaneously: it provides mechanical support for LED modules, establishes electrical connections through printed traces, enables heat dissipation pathways, and allows geometric flexibility for aesthetic design. This multi-functionality eliminates the need for separate dedicated components for each function.
3Temperature
If heat dissipation structures are added to LED lamps, then thermal management is improved, but aesthetic design freedom is restricted
Solution Approach 1:
The flexible PCB itself serves as a heat dissipation structure through its layered construction and material properties. The flexible nature of this thermal management solution allows it to conform to various aesthetic lamp shapes without requiring rigid heat sinks or fixed geometric thermal pathways that would constrain design freedom.
Solution Approach 2:
The flexible PCB structure performs dual functions: electrical connectivity and thermal management. The same flexible substrate that enables aesthetic shape freedom also provides heat dissipation pathways through its material composition and structural design, eliminating the need for separate aesthetic-compromising heat sink components.
4Ease of operation
If multiple separate components are used in LED lamps, then functional requirements are met, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent consolidates multiple separately manufactured components into a single integrated flexible PCB assembly. LED modules, driver circuits, control electronics, and mounting structures are all integrated onto one substrate, transforming a multi-step assembly process involving multiple components into a simpler single-unit manufacturing and installation process.
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 reduces assembly time, enhances reliability and safety, and offers design flexibility while maintaining low energy consumption, making the lamp competitive and aesthetically versatile.
Implementation Method 1
a layer of heat-conducting adhesive for the direct application of which to the supporting structure the flexible element is provided
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A low-consumption lamp (1) with light sources of the LED type comprising a supporting structure (2) made of a material that dissipates heat to which is connected a flexible element (10) that supports the LED sources (11), a wiring (30) for the electric power supply of the LED sources, a power switch (22) and a capacitive luminous intensity regulator (23) activatable by touching, the flexible element (10) being associated with the supporting structure (2) by means of a layer of heat-conducting adhesive (40).