Flexible Light Engine Bus Bar Interconnector Stamping
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Solution Overview
Problem
Conventional methods for manufacturing flexible LED light engines are costly and inefficient, requiring expensive masks and inconvenient etch materials, and often involve batch processing, which limits flexibility and increases production costs.
Innovation Solution
A roll-to-roll manufacturing method is developed using electrically insulating laminate sheets with perforations and conductive bus bars, where metallic strips are connected via interconnectors and laminated between the sheets to form conductive paths for LED circuits, allowing for continuous production of flexible light engines with high thermal conductivity and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional lithographic process with copper foil and FR4 is used, then circuit boards can be manufactured, but the process requires expensive masks, batch processing, and inconvenient etch materials which increases cost and reduces efficiency
Solution Approach 1:
The patent replaces the conventional lithographic etching process with a mechanical stamping process. A stamp with pre-formed circuit patterns is pressed onto the copper-clad flexible substrate to create conductive traces through localized copper removal or displacement, eliminating the need for chemical etchants, masks, and batch processing while enabling continuous production
Solution Approach 2:
The patent changes the manufacturing approach from chemical-based (etching) to mechanical-based (stamping). This parameter change in the manufacturing method enables continuous roll-to-roll production, removes the need for expensive photoresist masks and etch baths, and significantly improves production efficiency while maintaining circuit precision
2Adaptability or versatility
If flexible substrate with LED circuits is used, then lighting applications can be implemented, but conventional manufacturing methods increase production costs and reduce flexibility
Solution Approach 1:
The patent replaces expensive conventional lithographic manufacturing with a mechanical stamping process that uses simple metal stamps to create circuit patterns on flexible substrates. This eliminates the need for costly photoresist masks, etch materials, and batch processing equipment, enabling cost-effective continuous production of flexible LED light engines
Solution Approach 2:
The patent segments the manufacturing process into discrete stamping operations where individual circuit patterns are created by pressing stamped elements onto the flexible substrate. This segmentation allows for modular, continuous production and easy adaptation to different circuit designs without requiring complete process retooling
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
This method enables the efficient and cost-effective production of flexible light engines with high thermal conductivity and heat dissipation, maintaining LED junction temperatures below 50°C, thereby extending LED lifespan and improving lighting efficiency, while reducing production costs and environmental impact.
Implementation Method 1
forming electrically conductive first and second metallic bus bars 20, 22 in a single conductive layer on at least one of the lower and upper laminate sheets 12, 14; forming electrically conductive interconnectors 30
Implementation Method 2
This method enables the efficient and cost-effective production of flexible light engines with high thermal conductivity and heat dissipation, maintaining LED junction temperatures below 50°C
Implementation Method 3
retaining the metallic strip 40 between the lower laminate sheet 12 and the upper laminate sheet 14 by laminating the lower laminate sheet 12 with the upper laminate sheet 14
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A flexible light engine, comprising insulating lower and upper laminate sheets; first and second electrically conductive metallic bus bars between the sheets; a plurality of electrically conductive metallic conductors between the sheets being disposed laterally between the bus bars, wherein each conductor defines two metallic contacts exposed in register with adjacent perforations in the perforated upper sheet; wherein each of the bus bars further comprises respective at least two interconnectors, and wherein the conductors are connected to respective interconnectors to define at least two series circuits and connectable in parallel between the bus bars, wherein each of the series circuits comprises a subset of the plurality of metallic conductors; and a plurality of LEDs attached to the contacts defining at least two series LED strings and connected in parallel between the bus bars, each said LED string comprising a plurality of LEDs.