Flexible Vehicle Warning Light for Curved Surface Mounting
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Solution Overview
Problem
Existing directional warning lights for vehicles face challenges in conforming to curved surfaces due to their rigidity, which is exacerbated by the large footprint of electronics required for flashing modes and heat generation, necessitating bulky adapters and non-flashing illumination modes.
Innovation Solution
A flexible directional warning light with bendable optic, backing, circuitry, and segmented heatsink allows for mounting on both flat and curved surfaces without specialized adapters, featuring a microcontroller for LED control and heat dissipation through a flexible substrate and heatsink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rigid directional warning lights are used, then the structure is simple and manufacturing is easy, but the device cannot conform to curved vehicle surfaces without bulky adapters
Solution Approach 1:
The patent employs flexible materials throughout the light device including a flexible printed circuit board for electronics, a flexible optic housing, and a flexible lens assembly. These flexible components allow the entire device to bend and conform to curved vehicle surfaces without requiring rigid mechanical adapters, directly resolving the contradiction between adaptability and structural complexity
Solution Approach 2:
The optic housing is divided into multiple segments that can flex relative to each other, allowing the housing to bend while maintaining the integrity of internal components. This segmentation enables the device to adapt to curved surfaces without compromising structural simplicity or manufacturing ease
2Adaptability or versatility
If electronics with large footprint are used for flashing control, then flashing warning functionality is achieved, but bendability of the lighting device is hindered
Solution Approach 1:
The patent uses a flexible printed circuit board (FPCB) instead of rigid circuit boards. The FPCB can be bent to various degrees while maintaining electrical connectivity, allowing the electronics to conform to curved surfaces. This flexible circuit board technology enables both flashing functionality and bendability simultaneously, resolving the contradiction between adaptability and electronics footprint
3Adaptability or versatility
If conventional heat dissipation methods are used, then heat management is effective, but the device rigidity increases hindering flexibility
Solution Approach 1:
The patent employs a flexible heatsink structure that can bend while maintaining thermal contact with heat-generating components. This flexible heatsink allows heat dissipation functionality to be preserved while enabling the device to conform to curved surfaces, resolving the contradiction between flexibility and temperature management
Solution Approach 2:
The patent uses composite material structures combining flexible substrates with thermally conductive materials. These composite constructions provide both the flexibility needed for curved surface mounting and the thermal conductivity required for effective heat dissipation, simultaneously addressing both requirements
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
Enables a single device to conform to various vehicle surfaces, providing flexible mounting options while maintaining effective heat management and flashing functionality without the need for cumbersome mechanical adapters.
Implementation Method 1
heat dissipation through a flexible substrate and heatsink
Data Source
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AI summary
Disclosed is a directional warning light designed to bend along its longitudinal axis up to about 30° so as to conform to curved vehicle surfaces. Flexible components of the disclosed embodiments allow the bending and include a bendable optic, bendable base, and bendable circuit substrate.