Flexible Lighting Module Meander Leads for Complex Surface Mounting
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Solution Overview
Problem
Conventional solid-state lighting modules are inflexible and unable to be mounted on surfaces with complex structures, particularly those with bends parallel to the plane of the substrate, due to their non-elastic nature, limiting their application in environments like vehicles with intricate designs.
Innovation Solution
The implementation of meander structures in electrically conductive leads on a flexible printed circuit (FPC) substrate, combined with strategically placed cut-outs, allows for bending around radii parallel to the plane, enabling the module to conform to complex shapes by creating stretchable regions that maintain mechanical stability and avoid web inhibition at bending points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rigid substrates are used for SSL lighting modules, then manufacturing simplicity and structural stability are maintained, but the module cannot be mounted on surfaces with complex geometries requiring bending parallel to the substrate plane
Solution Approach 1:
The substrate is divided into rigid regions and flexible regions, where the flexible regions contain meander structures that can be bent parallel to the substrate plane. This segmentation allows different parts of the substrate to serve different functions: rigid parts provide structural stability while flexible parts enable adaptation to complex surface geometries.
Solution Approach 2:
The substrate transitions from a completely rigid structure to a dynamic structure with flexible regions containing meander patterns. These meander structures can dynamically deform parallel to the substrate plane when mounted on curved surfaces, while maintaining electrical connectivity through the conductive leads.
2Adaptability or versatility
If the substrate is made fully flexible to enable bending on complex surfaces, then mounting versatility improves, but mechanical stability and structural integrity deteriorate
Solution Approach 1:
Different regions of the substrate have different mechanical properties: rigid regions maintain structural stability and support components, while flexible regions with meander structures provide bending capability. This local differentiation of material properties resolves the contradiction between overall flexibility and local stability.
Solution Approach 2:
The substrate functions as a composite structure combining rigid and flexible regions within the same substrate. The rigid regions provide structural backbone while flexible regions with meander patterns provide adaptability, creating a composite system that exhibits both stability and flexibility.
3Adaptability or versatility
If meander structures are added to conductive leads to enable planar bending, then adaptability to complex surfaces improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The meander structures are merged directly into the conductive leads during the PCB manufacturing process, rather than being added as separate components. This integration allows the meander patterns to be created using standard PCB trace routing, maintaining ease of manufacture while achieving planar bending capability.
4Adaptability or versatility
If cut-outs are provided adjacent to meander loops to enable bending, then flexibility for complex surface mounting improves, but structural integrity and potential weak points increase
Solution Approach 1:
The cut-outs are pre-positioned adjacent to the meander loops during substrate design, creating predetermined bending zones that guide the deformation behavior. This preliminary structural arrangement ensures that bending occurs in controlled locations rather than creating unpredictable stress concentrations.
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 solution allows for the flexible mounting of solid-state lighting modules on arbitrary surfaces, including those with complex geometries, enhancing their adaptability and durability while maintaining mechanical stability and avoiding mechanical stress on components.
Implementation Method 1
by forming electrically conductive leads that interconnect the light emitting elements and any further electronic components as meander loops, and by additionally providing cut-outs close to these meander loops, a sufficient resiliency can be achieved for the flat flexible substrate being bendable also around a radius that is essentially parallel to the plane defined by the flat flexible substrate
Data Source
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AI summary
The present invention relates to a lighting module comprising a flat flexible carrier (132) having at least one electrically insulating flexible substrate (104) with at least one planar electrically conductive lead (106), at least one light emitting element (102) and at least one electronic component (124), the light emitting element (102) and the electronic component (124, 126) and/or a second light emitting element (102) being electrically connected to each other by means of said at least one electrically conductive lead (106). In at least one stretchable region, said conductive lead (106) is patterned to form at least one meander loop, wherein said substrate (104) has at least one cut-out (114) that is provided adjacent to the meander loop in a way that the at least one meander loop partly encircles the cut-out (114).