Flexible PCB LED Module for Curved Channel Letters
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Solution Overview
Problem
Conventional channel letter lighting systems face challenges with rigidity, flexibility, and installation complexity due to the need for cutting and splicing of LED ribbon products, which limits their ability to conform to curved surfaces and requires tedious soldering, making them unsuitable for low-profile and custom 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 cutting, using a housing that covers part of the PCB to direct light and a perforated design for separable sections that maintain electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rigid PCB modules are used, then structural stability is maintained, but flexibility and adaptability to curved surfaces are lost
Solution Approach 1:
The patent applies a flexible PCB (flexible printed circuit board) that combines the electrical functionality of a rigid PCB with the flexibility of a thin film structure. The flexible PCB includes a flexible substrate with conductive traces that can bend and conform to curved surfaces while maintaining electrical connections, thus resolving the contradiction between structural stability and adaptability to curved surfaces.
2Adaptability or versatility
If flexible LED ribbon products are used, then adaptability to different shapes is improved, but installation complexity increases due to cutting and splicing requirements
Solution Approach 1:
The flexible PCB is designed with predefined segmentation features including perforations and tear-off tabs at regular intervals. These segmentation features allow installers to easily divide the continuous flexible PCB into smaller sections by simply tearing or pulling at the tabs, eliminating the need for complex cutting and splicing operations while maintaining the flexibility and shape adaptability of the LED ribbon product.
3Adaptability or versatility
If flexible LED ribbon products are used, then shape adaptability is improved, but installation time increases due to tedious soldering requirements
Solution Approach 1:
The conductive traces and connection points on the flexible PCB are pre-designed and pre-positioned during manufacturing. The segmentation features with tear-off tabs are pre-placed at regular intervals along the flexible PCB. This preliminary preparation allows installers to quickly divide and install the flexible PCB without time-consuming soldering operations, as the electrical connections are already established through the flexible PCB's integrated circuit design.
4Manufacturing precision
If closely spaced LEDs are used in flexible ribbon products, then light distribution uniformity is improved, but device complexity increases due to cutting and splicing needs
Solution Approach 1:
The flexible PCB with closely spaced LEDs is segmented into manageable sections through predefined perforations and tear-off tabs. This segmentation allows the uniformly illuminated flexible PCB to be easily divided into smaller installation sections without compromising the light distribution uniformity achieved through the closely spaced LED configuration, thus resolving the contradiction between manufacturing precision and device complexity.
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 cost-effective, efficient, and reliable lighting system that can be easily installed by a single individual, offering even light distribution and flexibility to conform to different channel letter housing shapes, reducing installation time and complexity while maintaining the integrity of the light emitting elements.
Implementation Method 1
at least one light emitting element on the PCB... adapted to emit light in a direction away from the housing, in response to the electrical current supplied by the conductors
Data Source
AI summary
The invention described herein is directed to different embodiments of a low profile lighting unit 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.