Flexible Sheet Lighting Device for Rigid Tube Adaptability
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Solution Overview
Problem
Traditional lighting devices with rigid tubes limit flexibility and manufacturing efficiency when using LEDs, making them less adaptable for various applications and functionalities.
Innovation Solution
A lighting device featuring a flexible sheet assembly that can be rolled into a tubular shape, incorporating a light source within, with integrated optical and reflective layers for efficient light distribution and thermal management, allowing for easy assembly and integration of functionalities without external reflectors or additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid tube is used for the lighting device, then structural strength and stability are improved, but flexibility in manufacturing and installation deteriorates
Solution Approach 1:
The patent applies the dynamics principle by transitioning from a rigid, fixed structure to a flexible, adaptable one. The lighting device uses a flexible circuit board that can be bent and shaped into various configurations, allowing the same structural component to adapt to different manufacturing processes and installation environments while maintaining electrical connectivity and structural integrity.
Solution Approach 2:
The patent directly implements this principle by replacing the traditional rigid tube with a flexible circuit board structure. This thin, flexible film allows the lighting device to be manufactured using roll-to-roll processes and installed in various orientations and shapes, significantly improving manufacturing flexibility and installation adaptability while maintaining the necessary structural support through the circuit board's design.
2Reliability
If multiple separate components are used for reflectors and optical elements, then functional performance is improved, but device complexity and manufacturing cost deteriorate
Solution Approach 1:
The patent applies the merging principle by integrating multiple optical functions into a single unified structure. The flexible circuit board incorporates reflective surfaces, optical guiding elements, and light distribution features all in one component, eliminating the need for separate reflectors and optical elements. This reduces assembly steps, lowers manufacturing cost, and simplifies the overall device while maintaining functional performance.
Solution Approach 2:
The patent implements multi-functionality by designing the flexible circuit board to simultaneously serve as the structural support, electrical circuit carrier, optical reflector, and light distribution element. This universal component performs multiple functions that traditionally required separate parts, reducing device complexity and improving manufacturing efficiency without compromising functional performance.
3Manufacturing precision
If traditional manufacturing processes are used, then manufacturing precision is improved, but productivity and cost-effectiveness deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-forming the flexible circuit board with integrated optical features and electrical circuits before final assembly. The circuit board is manufactured with precise electrical traces and optical patterns already in place, allowing for rapid assembly into the final lighting device. This pre-preparation enables high-speed manufacturing while maintaining precision through controlled fabrication processes.
Solution Approach 2:
The patent replaces traditional mechanical assembly processes with a flexible circuit board system that can be manufactured using printed circuit board techniques and flexible fabrication methods. This substitution enables continuous manufacturing processes with higher productivity while maintaining assembly precision through the inherent accuracy of modern PCB fabrication and flexible material handling.
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 sheet assembly enables cost-effective, flexible, and efficient manufacturing of lighting devices with improved optical and mechanical properties, enhanced light distribution, and thermal management, providing a safer and more versatile lighting solution.
Implementation Method 1
The sheet assembly is adapted to be rolled into a tube
Implementation Method 2
at least one transparent or translucent portion for providing the light exit surface
Implementation Method 3
The first layer is preferably provided to the flexible sheet assembly... which is advantageous for providing a smooth light output
Implementation Method 4
The first optical layer is one of a diffusing layer and a wavelength converting layer
Implementation Method 5
The first optical layer is one of a diffusing layer and a wavelength converting layer, which is advantageous for providing a smooth light output
Data Source
AI summary
There is provided a lighting device and a method to manufacture such a lighting device. The inventive concept is based on manufacturing a lighting device on an at least partly flexible sheet assembly which is rolled into a tube, such that the light source of the lighting device is arranged within the tube. The flexible sheet assembly is arranged such that the tube provides a light mixing chamber and light exit surface for the lighting device. Thus, the tube shaped lighting device instantly delivers the necessary optical and mechanical properties for easy assembly and the functionality of a light engine.