Flexible LED Strip Segmented Zones for 3D Bending
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Solution Overview
Problem
Flexible printed-circuit strips are limited in their bending capabilities, allowing mobility only along bend lines parallel to their plane, leading to potential damage and destruction of electronic components when bent perpendicular to the plane, restricting their application in flexible electronics like LED luminaires.
Innovation Solution
A flexible printed-circuit strip is subdivided into alternating surface zones with connecting webs that allow bending about multiple axes, including those perpendicular to the strip's plane, enabling three-dimensional deformability by orienting surface zones on different planes and using connecting webs to manage stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible printed-circuit strip is formed substantially on a single plane, then mobility and bendability along bend lines parallel to the plane are achieved, but bending about an axis perpendicular to the plane causes the strip to buckle and damage electronic components
Solution Approach 1:
The printed-circuit strip is segmented into multiple surface zones (first and second surface zones) that are laterally offset from each other, allowing independent movement and stress distribution during bending operations
Solution Approach 2:
The invention transitions from a single-plane structure to a multi-plane structure by laterally offsetting surface zones and introducing connecting webs at angles, enabling three-dimensional bending capabilities including perpendicular axes
2Reliability
If a flexible printed-circuit strip is cast in a casing to provide hermetic seal, then protection and sealing are achieved, but the strip cannot buckle at the edge and becomes vulnerable to damage during perpendicular bending
Solution Approach 1:
The cast structure is segmented into multiple surface zones that can move independently, allowing the sealed unit to bend in multiple directions without compromising the hermetic seal or causing component damage
Solution Approach 2:
The connecting webs are designed with flexible angles to the longitudinal direction, enabling dynamic adaptation to bending forces from different directions while maintaining the structural integrity of the sealed casing
3Adaptability or versatility
If multiple variants of flexible LED luminaires with different bending directions are produced, then specific bending requirements are met, but device complexity and variety of configurations increase
Solution Approach 1:
A single luminaire design with laterally offset surface zones and angled connecting webs can bend about multiple perpendicular axes, replacing the need for multiple specialized variants and simplifying the product family
Data Source
AI summary
The invention relates to a flexible printed-circuit strip to whose upper face and/or lower face electronic components can be or are mounted, wherein it is subdivided in the direction of its longitudinal extension (L) into first and second surface zones (F1, F2) and it is subdivided perpendicular to the longitudinal direction (L) into a first edge region (SB1) and a second edge region (SB2), the two strip portions (SB1, SB2) being on both sides of a common longitudinal line (LL), wherein all the first surface zones (F1) are arranged in the first edge region (SB1) and all the second surface zones (F2) are arranged in the second edge region (SB2), and wherein first and second surface zones (F1, F2) that are adjacent in longitudinal direction (L) are respectively connected by a connecting web (V) that crosses the longitudinal line (LL). The invention further relates to a flexible printed-circuit strip that is subdivided in the direction of its longitudinal extension (L) into first and second surface zones (F1, F2) in the direction of its longitudinal extension (L), wherein the first surface zones (F1) are arranged on a first plane and the second surface zones (F2) are arranged on a second plane that is oriented differently from the first, and wherein a connecting web (V) that extends perpendicular to the longitudinal direction (L) is embodied so as to be bent about a bend line (BL) that is parallel to the longitudinal direction (L). The invention also relates to an LED luminaire comprising such a printed-circuit strip.