Flexible LED Support Structure with Segmented Cavities
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Solution Overview
Problem
Rigid substrates used in light emitting diodes (LEDs) restrict the flexibility of lighting devices, making it difficult to design and install them in various environments, such as automotive applications where flexible lighting solutions are desired.
Innovation Solution
A support structure comprising an inner transparent housing portion, an outer housing portion with reflective surfaces, and connection members that allow for mechanical coupling and flexibility, enabling the use of flexible LED strips with small, low-power LEDs and a phosphor material for white light emission, while also decoupling thermal deformations and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid substrates are used to support light emitting elements, then structural stability is improved, but flexibility of the lighting device deteriorates
Solution Approach 1:
The support structure is divided into multiple discrete fastening elements distributed across the substrate, rather than using a single rigid support. This segmentation allows each element to independently accommodate local deformations while maintaining overall structural integrity, enabling both stability and flexibility.
Solution Approach 2:
The patent employs a flexible substrate with distributed fastening elements that can bend and deform without breaking. This flexible construction with strategic support points allows the lighting device to be installed on curved or irregular surfaces while maintaining structural stability through the distributed fastening system.
2Manufacturing precision
If rigid substrates are used, then manufacturing precision is improved, but adaptability to different installation environments deteriorates
Solution Approach 1:
The support structure uses multiple discrete fastening elements instead of a continuous rigid substrate. This segmentation maintains manufacturing precision for each individual element while allowing the overall structure to adapt to various installation environments through flexible arrangement and positioning of the distributed elements.
Solution Approach 2:
The support structure transitions from a static rigid substrate to a dynamic flexible system with distributed fastening elements. This dynamic construction allows the lighting device to maintain precise positioning where needed while adapting its shape and configuration to different installation environments.
3Illumination intensity
If transparent materials are used for housing portions, then light transmission is improved, but mechanical strength deteriorates
Solution Approach 1:
The housing is constructed using composite material systems that combine transparent materials with reinforcing structures. The transparent portions maintain excellent light transmission while the composite construction provides enhanced mechanical strength through the integration of different material properties and structural configurations.
Solution Approach 2:
The housing is divided into transparent panels or sections that are strategically positioned to maximize light transmission while maintaining structural integrity. The segmented construction allows transparent materials to be used where light transmission is critical while other structural elements provide the necessary mechanical strength.
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 provides a flexible and robust lighting system that can be bent in all directions, offers homogeneous light distribution, and enhances reliability by decoupling thermal deformations, while reducing material usage and preventing hot spots, thus improving the design and installation of lighting devices in various environments.
Implementation Method 1
The outer housing portion includes at least a bottom wall, a first side wall and a second side wall, each having reflective inner surfaces
Implementation Method 2
enabling the use of flexible LED strips with small, low-power LEDs and a phosphor material for white light emission
Data Source
AI summary
Support structures and lighting systems including the support structure and a lighting device are described. A support structure includes an inner housing portion, an outer housing portion and connection members. The inner housing portion is transparent and has at least one portion shaped to conform to the lighting device. The outer housing portion includes at least a bottom wall, a first side wall and a second side wall, each having reflective inner surfaces, to form a container. The connection members are transparent and mechanically connected between the inner housing portion and the outer housing portion to support the inner housing portion and divide a region of the container between the inner housing portion and the outer housing portion into first cavities, each enclosed by at least one of the bottom wall, the first side wall or the second side wall and at least one of the connection members.