Flexible PCB LED Thermal Protection for Phototherapy
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Solution Overview
Problem
Current phototherapy devices for infant jaundice treatment can cause excessive skin heating due to light emitting diodes (LEDs), which is a safety concern as they lack effective thermal management, and this is not adequately addressed by existing designs that often require multiple components and complex assembly processes.
Innovation Solution
A phototherapy device integrated with LEDs and thermal protection components on a flexible printed circuit board (PCB) that includes a temperature sensor to monitor skin temperature, automatically turning off the LEDs when a maximum temperature is reached and turning them back on when it drops below a safe threshold, thereby ensuring safe thermal conditions during treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are used for phototherapy treatment, then phototherapy effectiveness is improved, but skin overheating risk increases
Solution Approach 1:
The patent implements a feedback control system where a temperature sensor continuously monitors the temperature of the patient's skin through the flexible PCB. When the temperature exceeds a predetermined safe threshold, the control circuit automatically reduces or shuts off power to the LEDs, preventing overheating. This closed-loop feedback mechanism resolves the contradiction by dynamically adjusting LED operation based on real-time temperature data, maintaining both treatment effectiveness and safety.
Solution Approach 2:
The flexible PCB serves as an intermediary element that integrates multiple functions: it provides structural support for mounting LEDs, incorporates temperature sensors to monitor skin temperature, and acts as a thermal interface between the LEDs and the patient's skin. This intermediary structure enables both effective light delivery and safe thermal management, resolving the contradiction between phototherapy effectiveness and overheating risk.
2Reliability
If multiple separate components are used for LEDs and thermal protection, then functional reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the LED array, temperature sensors, control circuitry, and flexible PCB into a single integrated phototherapy device. The flexible PCB serves as a common platform that mechanically and electrically integrates all components, eliminating the need for separate assemblies and reducing overall device complexity while maintaining functional reliability through the unified design.
Solution Approach 2:
The flexible PCB performs multiple functions simultaneously: it provides structural support, electrical connectivity, temperature sensing, and thermal management. This multi-functional design eliminates the need for separate components for each function, reducing device complexity while maintaining reliability through the versatility of the integrated flexible circuit board.
3Ease of manufacture
If multiple components and assembly steps are used, then assembly flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
By combining all functional components (LEDs, temperature sensors, control circuits) onto a single flexible PCB, the patent dramatically simplifies the manufacturing process. The flexible PCB can be manufactured using standard rigid-flex PCB fabrication techniques, allowing all components to be mounted and interconnected in a single manufacturing step rather than requiring multiple assembly operations, thus reducing manufacturing complexity while maintaining assembly flexibility.
Solution Approach 2:
The use of a flexible PCB as the base structure allows the entire device to be manufactured as a thin, flexible assembly that can be easily folded, shaped, and integrated into infant clothing or blankets. This flexible film approach simplifies manufacturing compared to rigid multi-component assemblies, as the flexible PCB can be manufactured in various configurations and directly integrated into the final product without complex mechanical assembly steps.
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 reduces the risk of skin overheating, simplifies the device assembly by combining components, and lowers manufacturing complexity and costs, while ensuring effective phototherapy delivery within safe temperature limits.
Implementation Method 1
A temperature sensor is secured to the clothing item and positioned to measure a temperature proximate to the patient wearing the clothing item
Implementation Method 2
The illuminators include light emitting diodes (LEDs) mounted on at least one flexible printed circuit board (PCB)
Data Source
AI summary
A phototherapy device includes a clothing item. Illuminators are secured to the clothing item and arranged to illuminate at least a portion of a patient wearing the clothing item. The illuminators include light emitting diodes (LEDs) mounted on at least one flexible printed circuit board (PCB). A temperature sensor is secured to the clothing item and positioned to measure a temperature proximate to the patient wearing the clothing item. A control circuit is connected to receive the temperature from the temperature sensor and operative to turn off the illuminators responsive to the temperature exceeding a maximum permitted temperature.