Flexible LED Strips With Staggered Interconnects
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Solution Overview
Problem
Existing LED light strip connections using overlapping solder pads are fragile and prone to mechanical breakage under twist or pull forces, as they rely on solder joints for both mechanical and electrical connections.
Innovation Solution
A flexible LED support assembly with multiple layers, including a conductive layer for connecting LEDs, an insulating layer, and extended terminal connecting tabs with offset solder pads to reduce the risk of mechanical and electrical breakage, using a conductive adhesive for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overlapping solder pads with solder joints are used to connect LED light strip segments, then electrical connection is achieved, but mechanical strength and reliability deteriorate under twist or pull forces
Solution Approach 1:
The connecting tab is segmented into multiple layers (first layer with first pads, second layer with second pads) where each layer provides separate electrical connection paths. This segmentation allows the connection to distribute mechanical stress across multiple independent solder joints rather than relying on a single fragile solder joint, thereby improving both electrical reliability and mechanical strength.
Solution Approach 2:
The invention transitions from a two-dimensional overlapping pad configuration to a three-dimensional stacked layer configuration. The connecting tab extends through multiple layers with pads positioned at different depths (first layer and second layer), creating vertical separation between connection points. This dimensional change allows electrical connections to be made at multiple levels while providing mechanical reinforcement against twist and pull forces.
2Reliability
If traditional solder joints are used for connecting LED light strips, then electrical conductivity is achieved, but mechanical fragility increases under stress
Solution Approach 1:
The multi-layer structure with offset pads acts as a pre-designed mechanical cushioning system. When twist or pull forces are applied, the staggered pad configuration and multiple solder joints absorb and distribute the mechanical stress before it can reach critical levels that would cause breakage. This beforehand cushioning protects the electrical connection from harmful mechanical factors.
Solution Approach 2:
The connecting tab employs a composite structure combining multiple conductive layers with insulating materials between them. This composite construction provides both electrical conductivity through the conductive layers and mechanical strength through the layered architecture, creating a connection that resists mechanical breakage while maintaining electrical reliability.
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 enhances the mechanical and electrical robustness of LED light strip connections, reducing the likelihood of breakage when subjected to stress, compared to traditional solder joint methods.
Implementation Method 1
The LED assembly can include a second flexible circuit electrically and mechanically coupled to the first terminal extended electrically connecting tab using a conductive adhesive
Data Source
AI summary
A flexible light emitting diode (LED) circuit having a first layer, the first layer including a conductive material configured to connect to an LED die, a second layer, the second layer including an electrically insulating material, and a third layer positioned between the first and second layer, the third layer having a first terminal extended electrically connecting tab that extends outward beyond the first layer and the second layer.