Flexible PCB LED Module for Channel Letter Adaptation
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Solution Overview
Problem
Conventional channel letter lighting systems face challenges with rigidity, flexibility, and installation complexity due to rigid modules and inflexible LED ribbon products, which result in uneven light distribution and increased installation time and cost, especially in low-profile and curved applications.
Innovation Solution
A flexible low-profile lighting unit comprising a flexible printed circuit board (PCB) with light emitting elements and conductors that can be bent and twisted to accommodate various shapes, allowing for easy installation and customization without the need for cutting or splicing, and featuring a housing that exposes light emitting elements for efficient light distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional rigid PCB modules are used, then structural stability is improved, but adaptability to different shapes and curves deteriorates
Solution Approach 1:
The patent transitions from rigid PCB modules to flexible PCB modules that can dynamically adapt to different mounting surfaces. The flexible PCB maintains structural integrity while enabling bending and conforming to various shapes, resolving the contradiction between stability and adaptability.
Solution Approach 2:
The patent employs flexible PCB technology where the circuit board itself becomes a flexible substrate that can conform to curved and irregular surfaces. This flexible thin film structure maintains electrical connectivity while adapting to different geometries, solving the contradiction between structural stability and shape adaptability.
2Adaptability or versatility
If conventional flexible LED ribbon products are used, then adaptability to different shapes is improved, but device complexity increases due to cutting and splicing requirements
Solution Approach 1:
The flexible PCB module incorporates pre-defined separation lines that allow clean segmentation without complex splicing. Installers can separate modules at designated points while maintaining electrical connectivity through built-in contact pads, eliminating the need for soldering and reducing installation complexity.
Solution Approach 2:
The patent introduces intermediary contact pads and conductive elements embedded in the flexible PCB that facilitate electrical connection between separated sections. These intermediaries enable module separation while maintaining circuit continuity, reducing installation complexity compared to traditional splicing methods.
3Adaptability or versatility
If conventional flexible LED ribbon products are used, then adaptability to different shapes is improved, but installation time increases due to cutting and splicing operations
Solution Approach 1:
The flexible PCB modules are pre-configured with separation lines and electrical connection elements during manufacturing. This preliminary preparation allows installers to simply separate and connect modules without time-consuming cutting, stripping, and soldering operations, significantly reducing installation time while maintaining shape adaptability.
Solution Approach 2:
The module design enables self-contained electrical connections through built-in contact pads and conductive traces on the flexible PCB. The system serves itself by incorporating all necessary connection elements, eliminating the need for external soldering tools and materials, and reducing installation time.
4Ease of manufacture
If conventional rigid PCB modules are used, then ease of manufacture is improved, but uniformity of light distribution deteriorates in narrow cavities
Solution Approach 1:
The flexible PCB allows the light-emitting module to conform to narrow and irregular cavity shapes, ensuring uniform light distribution across the mounting surface. The flexibility enables close spacing of LEDs in confined areas, improving illumination uniformity while maintaining manufacturing simplicity.
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 flexible lighting unit provides uniform illumination and easy installation on complex surfaces, reducing installation time and cost while maintaining a low profile, overcoming the limitations of traditional systems by allowing for seamless adaptation to different channel letter housing shapes.
Implementation Method 1
at least one light emitting element on the flexible PCB... The light emitting elements are adapted to emit light in a direction away from the housing
Implementation Method 2
The flexible PCB is adapted to conduct and dissipate heat from the light emitting elements
Data Source
Figure 1~3
Figure 4~5c
Figure 6a~6b
AI summary
The invention described herein is directed to different embodiments of a low profile lighting unit (300) that in some embodiments is adapted to conform to the shape of the mounting surface and/or adapted to be adjustable so as to be arranged in different configurations to accommodate various lighting applications.