Conductive Pathway on Flexible Sheet Using Metal Clips
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Solution Overview
Problem
Existing flexible substrate strip LED light engines lack an efficient and reliable method to form an electrically conductive pathway on an insulating sheet that effectively connects multiple electrical components while maintaining flexibility and durability.
Innovation Solution
A conductive pathway is created on a flexible, electrically insulating sheet using a plurality of metal clips with a polygonal cross-section, specifically rectangular, and apertures that allow the clips to be securely fastened, forming a robust electrical circuit for solid-state lighting sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal clips are used to form conductive pathways on an insulating sheet, then electrical connectivity and durability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The conductive pathway is segmented into discrete metal clips positioned at specific locations on the insulating sheet. Each clip serves as an independent electrical contact point, allowing for modular assembly and replacement. The clips are arranged in sequences that define conductive pathways through the insulating sheet, enabling flexible circuit design without continuous conductive layers.
Solution Approach 2:
The insulating sheet acts as an intermediary substrate that mechanically supports and electrically isolates the metal clips. This intermediary structure enables the clips to maintain precise spatial relationships while preventing unwanted electrical contact, thereby achieving reliable connectivity through controlled contact points rather than continuous conductors.
2Strength
If metal clips with depending legs are used to create conductive pathways, then mechanical strength and durability are improved, but manufacturing precision requirements increase
Solution Approach 1:
The metal clips are pre-formed with depending legs that are designed to engage with specific features on the insulating sheet before final assembly. The clips are manufactured with predetermined geometries including bent legs that will automatically position themselves at correct locations and orientations when attached to the sheet, reducing the precision requirements during the assembly process.
Solution Approach 2:
The metal clips exhibit local quality variations in their structure - the body portion provides electrical conductivity while the depending legs provide mechanical anchoring. The legs are specifically designed with bending characteristics and engagement features that localize the positioning function to specific regions of the clip, ensuring accurate placement without requiring high precision throughout the entire manufacturing process.
3Adaptability or versatility
If multiple metal clips are distributed on an insulating sheet to form pathways, then adaptability and flexibility are improved, but device complexity increases
Solution Approach 1:
The electrical circuit is segmented into discrete functional units represented by individual metal clips and their associated contact points on the insulating sheet. This segmentation allows the circuit to be configured in different patterns (series, parallel, or combinations) by selectively positioning and connecting clips, providing adaptability without requiring a complete redesign of the entire circuit structure.
Solution Approach 2:
The metal clips serve multiple functions simultaneously: they provide electrical contact points, define conductive pathways through their spatial arrangement, and offer mechanical support structures. The insulating sheet with its array of clip positions serves as a universal platform that can accommodate different circuit configurations using the same basic clip components, reducing the need for specialized parts for each configuration type.
Data Source
AI summary
A conductive pathway mounted on an electrically insulating sheet having an upper face and an opposed lower face, said sheet having a plurality of pairs of apertures; a plurality of electrically conductive clips, each clip being separated spatially from an adjacent said clip; each electrically conductive clip comprising a first body portion and first and second depending legs defining a sheet-receiving recess therebetween, said first body portion being disposed in contacting relation with said upper face of said sheet and said legs being disposed in contacting relation with said lower face of said sheet; each leg of one of said electrically conductive clips extending through one of said apertures of a pair of said apertures from said upper face to said lower face; and a plurality of electrical components each mounted in conductive relationship to two adjacent said conductive clips and bridging said insulating sheet.